Method of making a composite biotextile and a medical implant comprising such composite biotextile

ABSTRACT

Disclosed herein is a method of making a composite fabric for use in or as a medical implant component, the method comprising steps of providing a textile comprising at least one strand having titer of 2-250 dtex and comprising fibers made from a biocompatible and biostable synthetic polymer; determining locations on the textile where a cut is to be made for an intended use of the textile; optionally pretreating the textile at least at the determined locations on at least one side of the textile with a high-energy source to activate the surface; solution coating the textile at least at a determined location with a coating composition comprising a biocompatible and biostable polyurethane elastomer and a solvent for the polyurethane; removing the solvent from the coated textile; and laser cutting the coated textile as obtained at least a one coated location with an ultra-short pulse laser; to result in a composite biotextile wherein polyurethane is present in an amount of 2.5-90 mass % based on composite biotextile and polyurethane is present at least at a laser-cut edge. Such composite biotextile as made shows an advantageous combination of good biocompatibility, especially hemocompatibility, high strength and pliability, and has well-defined regular edges that have high suture retention strength. Further embodiments concern the use of such composite biotextile in or as medical implant component for an implantable medical device; such as in orthopedic applications and cardiovascular implants. Other embodiments include such medical devices or implants comprising said composite biotextile or medical implant component.

FIELD

The disclosed invention pertains to methods of making a biotextile, more specifically a medical implant component based on a modified polymeric textile like a woven fabric, to such component as obtained, and to use of such component in making a medical implant.

BACKGROUND

The term medical textile is generally used for a flexible material made of a network of fibers, which is used outside the body and not in contact with circulating blood or open wounds; like bandages, dressings, eye patches, incontinence products, braces, surgical drapes, face masks, etc. Biotextiles refer to non-viable, permanent or temporary, fibrous constructs like textiles created from synthetic or natural fibers, which are used either in an internal (inside the body) or external (outside the body) biological environment as a medical device for the prevention, treatment or diagnosis of an injury or disease, and as such serve to improve the health, medical condition, comfort and wellness of the patient. Examples of medical implants wherein a biotextile can be used include surgical sutures, hernia meshes, ligaments and tendons, and cardiovascular applications like patches, grafts and prosthetic heart valves. Requirements for fibers and textiles that can be used in implants relate to biocompatibility, biodegradability vs biostability, mechanical properties like strength, and purity (e.g. free from toxic substances, no surface contaminants like lubricants and sizing agents). Many surgical procedures that involve placing an implant can be performed using open or percutaneous/endoscopic surgical techniques. The latter minimal invasive approach is becoming more and more adopted due to clinical benefits such as faster recovery time of the patient. The increasing adoption rate of these types of procedures creates the need for a lower profile of the devices used, requiring biotextile products that also meet requirements of pliability; like compacting and compressing to fit within a narrow delivery system, without negatively affecting properties and performance of the textile or fabric in use. A fabric is a flexible textile made by interlacing one or more strands of fibers, for example by knitting, weaving or braiding; and generally, the textile has a thickness much smaller than other dimensions like length and width.

Examples of biocompatible and biostable fabrics include those made from fibers made from polyesters like polyethylene terephthalate (PET) and poly(l-lactic acid) (PLLA), or from polyolefin-based fibers; especially from thin, yet very strong monofilaments or multi-filament yarns made from ultra-high molecular weight polyethylene (UHMWPE). Such PET, PLLA and UHMWPE fibers are applied in or have been proposed for use in medical implants like sutures, meshes, (stent-)grafts and prosthetic valves.

For biomedical use, a textile or fabric often needs to be cut to a smaller piece of desired size or shape and/or be connected to another (implant or body) component for example via stitching or suturing. Generally, at least cut edges of such piece of fabric require some form of stabilization to increase its fraying or raveling resistance and its suture retention strength. Suture retention represents the ability of the fabric to resist tearing or unraveling due to tensile forces acting on a suture that passes through the fabric, usually to fix the fabric to some other component of a medical device such as a metallic stent. There are many challenges to stabilizing a cut edge of a textile that is used as a component of a permanent medical implant, particularly those implants delivered percutaneously and in direct blood contact. Specifically, disadvantages of typical stabilization techniques may include (i) additional profile of the component and device, thereby requiring a larger catheter to implant it, (ii) additional material that may not have optimal blood contact properties such as thrombogenicity, (iii) distortion of the cut edge biotextile morphology, (iv) insufficient bond strength of the stabilization material increasing the risk of embolization of foreign particulate in the blood stream, and (v) stiffening of the biotextile or reducing its pliability.

It is further known that physical properties like surface texture, roughness, porosity and pore size of a fabric have influence on interactions with bodily fluids and tissues; and that such properties may need to be adjusted for a given application to control e.g. clotting of blood, an innate inflammatory response, or tissue ingrowth.

Document U.S. Pat. No. 5,178,630 describes making a ravel-resistant woven synthetic vascular graft, i.e. a woven fabric made from polyethylene terephthalate yarns and incorporating a low melting fusible strand in the weave. After heat setting the fabric, the fusible component connects to neighboring other yarns and thus increases ravel resistance. The fusible strand may be a yarn formed from bicomponent filaments having a PET core and a lower melting polymer sheath. The document also describes a fabric with a fine low profile woven inner surface to promote smooth thin pseudointima formation and an external textured surface with yarn loops, like a velour surface, which texture would enhance tissue adhesion and ingrowth.

U.S. Pat. No. 5,741,332 relates to tubular soft tissue prostheses, like vascular grafts formed by weaving or braiding synthetic fibers. The document addresses problems such as fray-resistance of edges and controlling different porosities of internal and external surfaces. Multi-layered, three-dimensional braided structures are described, with either interlocking yarns connecting the layers or with separately formed layers being adhesively laminated. This approach would result in an inner layer with smooth surface and low porosity to prevent leakage and thrombus formation and an outer layer having a textured surface to enhance tissue ingrowth. The braided structure may further comprise a fusible material that is heat melted to bond to surrounding yarns to enhance ravel resistance and provide a graft more suitable for suturing to a body lumen. The braided structures are typically made from 20-1000 denier PET multi-filaments yarns and a lower melting fusible yarn.

U.S. Pat. No. 4,693,720 describes a surgical mesh comprising a woven fabric made from carbon fibers, to which—after having removed all non-biocompatible sizing that was present to enable fiber production—a first thin coating (or sizing) of a biodegradable polymer like polycaprolactone (PCL) is applied by solution coating to (re-)stabilize the fabric. A second coating layer is applied to the edges of the fabric using a solution of biodegradable polymer (e.g. PCL) with a higher concentration. The thus formed edging strip is indicated to be strong enough to support stitches or sutures when the device is surgically implanted. Alternatively, a polymer film strip may be applied to the edges and heated to melt coat the fabric edges.

In US2014/0374002 a method of making non-frayed, fused edges in a woven fabric is described; comprising directing heat on a section of the fabric for example with a nozzle expelling hot air, and then compressing the heated section to at least partially fuse the (partly) molten fibers. Subsequently, the fabric is cut at the fused sections, for example with a rotary knife, forming stabilized edges.

JP5111505 relates to making artificial blood vessels with good handleability and showing improved properties like sewing and fraying resistance. The document especially describes a prosthetic blood vessel made from ultrafine fibers of 0.8 dtex or less and 3-45 mass % (based on fibers) of a polymeric elastomer. More specifically, a tubular structure is formed from ultrafine fibers by weaving or other technique and elastomer is applied as a liquid to the structure by impregnating or coating, or preferably by thermally laminating a thin film. The elastomer does not fully cover fibers of the tubular structure and it is taught to apply the elastomer on the outside rather than on the inside of the tubular structure. Suitable polymeric elastomers include polyurethanes, polyureas, acrylics, styrene copolymers and natural rubber. In experiments, a tubular knitted structure was made from PET/polystyrene islands-in-sea fibers and the structure was then treated with trichloroethylene to remove the polystyrene component. The tubular fibrous construct was subsequently coated with a polyether urethane. The resulting structure showed good fraying resistance, sutureability and healing upon implanting in the aorta of dogs.

Despite the disclosures in the above documents, there still is a need for a method of making a textile suitable for use in biomedical applications, which biotextile combines biostability and biocompatibility with properties like high pliability, cuttability, fraying resistance and suture retention strength.

SUMMARY

Objects of the present disclosure include providing such method of making a biotextile, i.e. a textile for use in biomedical applications, which biotextile combines biostability and biocompatibility, high pliability and properties like suitable fraying resistance and suture retention strength, specifically at an edge made by cutting the biotextile; as well as such biotextile as obtained and use thereof in or as a medical implant component.

The embodiments as described herein below and as characterized in the claims provide a method of making a biotextile that combines several properties making it suitable for use as a component in making medical devices, especially in orthopedic and cardiovascular implants. In accordance with an aspect of the invention, this disclosure provides a method of making a composite textile for use in or as a medical implant component according to claim 1, more specifically a method of making a composite biotextile, the method comprising steps of

-   a. Providing a textile made from at least one strand having titer of     2-250 dtex and comprising fibers made from a biocompatible and     biostable synthetic polymer; -   b. Determining locations on the textile where a cut is likely to be     made for an intended use of the textile; -   c. Optionally pretreating the textile at least at the determined     locations on at least one side of the textile with a high-energy     source to activate the surface; -   d. Solution coating the textile at least at the determined and     optionally pretreated locations on at least one side of the textile     with a coating composition comprising a biocompatible and biostable     polyurethane elastomer and a solvent for the polyurethane; -   e. Removing the solvent from the coated textile; and -   f. Laser cutting the coated textile as obtained at a coated location     using an ultra-short pulsed laser;     to result in a composite biotextile wherein polyurethane is present     in an amount of 2.5-90 mass % based on composite biotextile, and     polyurethane is at least at a laser-cut edge.

It was found that such method of the invention results in a piece of composite biotextile that has been laser-cut at one or more coated locations to a desired size and/or shape, e.g. for its intended use as a component for a medical implant like as a graft material or as a valve leaflet, which composite biotextile has a well-defined and stable cut edge showing improved fraying resistance and suture retention compared to a corresponding non-coated and (laser-)cut textile. The inventors suggest, without wishing to be bound to any theory, that the polyurethane coating suitable covers and adheres to the fibers and that upon laser cutting the composite biotextile, the applied energy of the pulsed laser may shortly and locally increase the temperature to above the melting point of the polyurethane coating and of the polymer; possibly resulting in polyurethane, especially TPU, locally melting and further flowing around and connecting fibers, while the cut edge does not show local thickening and/or irregularities by melting and re-solidifying of fibers. Applying such polyurethane coating to the textile for use in an implant and requiring improved fraying resistance was not an obvious choice, because a coating may deteriorate other properties of the fabric, such as pliability, biostability, and importantly hemocompatibility. In addition, US2014/0296962 relating to prosthetic heart valves describes a braided construct made from polyester yarn and coated with for example a polyurethane for stabilizing and reducing permeability for use as graft material. Upon reading this document, however, the skilled person is taught that laser cutting a non-coated braid results in a cut edge that is sealed to prevent fraying; and that when a laser is applied for cutting the need for any coating to stabilize the fibrous construct is reduced or even eliminated.

Another advantage of the present method of making a composite biotextile is that by applying a coating at least at selected locations, the modified textile may further show improved interaction or biocompatibility when the resulting composite biotextile is used as a component in a medical implant, like excellent hemocompatibility and reductions in calcification and/or tissue ingrowth, in addition to properties like strength and pliability. This may be due to the chemical nature of the coating and/or to the coating partially covering and smoothening the relatively rough and porous surface of the textile composed of (multi-filament) fibers.

A further advantage of the composite biotextile as obtained by present method may be that the polyurethane can also function as an adhesive upon a further use of the biotextile. For example, the composite biotextile may be formed into a multi-layer flat or tubular structure by solvent- or heat-activated binding two or more layers together. Similarly, one or more coated textile layers may be laminated by solvent- or heat-binding to another fibrous construct like a cable, tape, or fabric to for example locally optimize properties; or to another article, for example be attached to a stent frame to form a (partly) covered stent, thus reducing the need for attachment means like clamps or sutures. Thermally binding of textiles composed of highly-crystalline synthetic fibers such as PET or UHMWPE, without such a coating, for example by using laser welding, generally distorts the textile morphology and/or its pliability.

Experimental results demonstrate marked improvements in hemocompatibility, abrasion resistance, and suture retention of the composite biotextile made by present method.

In accordance with another aspect, the present disclosure provides a composite biotextile for use in or as a medical implant component, which biotextile is obtainable by or obtained by the methods of this disclosure.

Further aspects concern the use of such medical implant component as a component of an implantable medical device and the use of such medical implant component in making an implantable medical device; especially for such applications wherein said component of a medical implant will be in contact with body tissue or fluids, such as in orthopedic applications including tissue reinforcement procedures or cardiovascular implants. Examples of materials for soft tissue reinforcement include meshes for hernia repair, abdominal wall reconstruction or degenerative tissue reinforcement. Cardiovascular implants include devices like a vascular graft, a stent cover, a mesh or a prosthetic valve, like a venous valve or heart valve. In many of such applications suturing is used to connect the implant component to other parts of a device or to surrounding soft or bone tissue.

Other aspects include such medical devices or implants comprising said composite biotextile or medical implant component.

A skilled person will understand that although the experiments are mainly relating to fabrics based on UHMWPE fibers and certain thermoplastic polyurethanes as coating, the disclosures may similarly apply to thin flexible textiles made from fibers of other polymers and which textiles are sensitive to edge fraying and suture induced raveling and tearing; and to using other polyurethane coating materials; as further indicated in the detailed description.

BRIEF DESCRIPTION OF FIGURES

FIG. 1 shows a photo micrograph of the laser-cut edge of UHMWPE woven fabric, as made with an ultra-short pulsed (USP) laser.

FIGS. 2A and 2B represent micrographs showing the laser-cut edge of UHMWPE laminated fabric (CE2), as made with USP laser (2A) and CM laser (2B).

FIGS. 3A and 3B show the laser-cut edges of polyurethane-coated UHMWPE fabric (Ex4), as made with USP laser (3A) and CM laser (3B).

FIGS. 4A and 4B show the laser-cut edges of other polyurethane-coated UHMWPE fabrics, as made with USP laser from sample Ex5 (4A) and with CM laser from 1-layer and 2-layer coated fabrics Ex5 and Ex6 (4B).

FIGS. 5A-5D show photo micrographs of the laser-cut edge part of samples having been exposed to abrasion testing; for uncoated UHMWPE fabric (CE7; FIG. 5A) and polyurethane-coated UHMWPE fabrics (Ex8-10; FIG. 5B-D).

DETAILED DESCRIPTION

Within the context of present disclosures following definitions are used. A fibrous construct is understood to comprise a structure made by interconnecting one or more strands of fibers, for example by interlacing, by using an adhesive or binder, or by partial melting; like a rope, cable, tape or textile. Ropes, cables and tapes are elongated constructs based on strands or fibers. A textile is a flexible material comprising a network of fibers, and typically has a thickness much smaller than its width and length, like a flat sheet having two sides or surfaces, or a hollow tubular form with inner and outer surfaces. Textiles include non-wovens, like a felt of randomly oriented fibers or a unidirectional sheet, and fabrics, like structures made from strands of fibers by techniques like knitting, crocheting, weaving, or braiding. A textile may be isotropic, that is have similar physical or mechanical properties in different directions; be anisotropic as a result of differences in type, number, and/or orientation of fibers; and may have a substantially constant thickness or show variations therein. A strand refers to a bundle of fibers. Fiber(s) is a general term referring to one or more slender (thin and long) threadlike structures; and encompasses continuous fibers (also called filaments) and/or short fibers (also called staple fibers) and may refer to a single fiber or filament and/or to a yarn. A filament is understood to be a (single) thin thread with a generally round or oblong cross-section with diameter generally below 50 μm and typically made by a (melt or solution) spinning process. A yarn is a continuous bundle of filaments and/or staple fibers, optionally twisted together to enhance yarn coherency. A multi-filament yarn is a bundle of filaments, like at least 5 filaments optionally twisted together to enhance yarn bundle coherency. A spun yarn is a thread made by twisting together staple fibers.

A composite fibrous construct, like a composite textile, refers to a construct that combines two or more structural elements; such as a woven fabric and another fibrous construct (like a cable, a tape, or another fabric) and/or a polymer composition (e.g. as a laminated or coated layer). A laminated textile is a textile having a layer of a polymer attached to one or two sides, which layer may have been applied by heat- or adhesive-bonding a polymer film or sheet, whereas a coated textile has a coating layer (e.g. of a polymer) on one or two sides or on a part thereof, which coating may have been applied as a solution, dispersion or melt, and which may have partially penetrated between or covered fibers of the textile.

A knitted or crocheted fibrous construct is made from at least one strand that is interconnected by looping around itself. A woven fibrous construct is made from at least 2 strands, with a-warp-strand running along the length of the construct and another-weft or fill-strand substantially perpendicular thereto; with warp and weft strands interlacing (crossing over and under each other) in a certain weave pattern. A braided fibrous construct is made from at least 3 strands interlacing one another in a diagonally overlapping pattern; and is typically a flat or a tubular construct of relatively narrow width. Non-woven fibrous constructs can be made from staple or continuous fibers bound together by chemical, mechanical, solvent and/or heat treatment(s); like a felt, or a spun-bound or needle-punched fiber web. The fibers may be randomly oriented such as in a felt but may also be substantially oriented in one (or more) directions. In the last case, and especially if bound together by laminating, coating or impregnating with a polymer, such construct may also be referred to as a unidirectional (UD) composite.

A biocompatible material is biologically compatible by not producing a toxic, injurious, or immunologic response when in contact with living tissue. Biodegradable means a material is susceptible to chemical degradation or decomposition into simpler components by biological means, such as by an enzymatic action. Biostable or bioinert means the material is substantially non-biodegradable under conditions and time of intended use.

In accordance with an aspect, the invention provides a method of making a composite biotextile suitable for use in or as a medical implant component, the method comprising steps of

-   a. Providing a textile comprising at least one strand having a titer     of 2-250 dtex and comprising fibers made from a biocompatible and     biostable synthetic polymer; -   b. Determining locations on the textile where a cut is likely to be     made for an intended use of the textile; -   c. Optionally pretreating the textile at least at the determined     locations on at least one side of the textile with a high-energy     source to activate the surface; -   d. Solution coating the textile at least at the determined, and     optionally pretreated, locations on at least one side of the textile     with a coating composition comprising a biocompatible and biostable     polyurethane elastomer and a solvent for the polyurethane; -   e. Removing the solvent from the coated textile; and -   f. Laser cutting the coated textile as obtained at least at a coated     location using an ultra-short pulsed laser;     to result in a composite biotextile wherein polyurethane is present     in an amount of 2.5-90 mass % based on composite biotextile and     polyurethane is at least present at a laser-cut edge.

The composite biotextile made can form part of or form a medical implant component, meaning that the biotextile forms a structural or strength providing part of such component, or the composite biotextile is a medical implant component. Examples of other items that may form part of the implant component include a metallic or polymeric stent frame as in case of some cardiovascular implants, or high-strength sutures, suture anchors, plates and screws, or other fixation structures in case of some orthopedic implants. Such implant components may be covered with a temporary protective compound or film for packaging, or may be compressed and crimped in a capsule, all of which parts can be removed before using the implant component. Such implants or components may also interact with an auxiliary part of the medical device, which part can serve as a tool in using the implant component to make an actual medical implant device; such as a percutaneous delivery system, an introducer sheath, suture passing devices, etc.

In embodiments of present invention, the medical implant component is a composite polyurethane/polymer biotextile and does not comprise further components, which simplifies use of the implant component in making an implant or device and reduces risk of introducing less or non-desirable parts or compounds.

In step a) of the method a textile, which comprises at least one strand having titer of 2-250 dtex and comprising fibers made from a biocompatible and biostable synthetic polymer, is provided. In embodiments, the textile is a non-woven construct or a fabric, which fabric can have been made with different forming techniques, like knitting, weaving or braiding. The fabric may be substantially isotropic or may show some anisotropy. The skilled person knows such textile and fabric forming methods and the different characteristics of such textiles; and will be able to select a suitable type given a specific intended application of the textile and its requirements. A knitted fabric, for example, has typically a more open structure than a woven fabric and may be easier to deform and extend. A specific property of a knitted fabric may be that e.g. extensibility may be different in different directions. Such anisotropic property may for example be useful in designing a component for a vascular device; like a graft of a stent or leaflets of a prosthetic valve. A woven structure has the advantage that desired non- or low-stretch properties, or certain shape, form or thickness, and variations therein, can be incorporated by applying various weaving techniques, or by using different yarns as warp and weft strands. This way a fabric having for example specific patterns, or anisotropic properties can be made. The skilled person will be able to select a suitable technique and interlacing pattern in combination with selected strands to obtain desired properties, optionally with some routine experiments.

In embodiments of the invention, the textile in the composite biotextile is a woven or knitted fabric, preferably a woven fabric. Typically, woven fabrics with commonly used patterns like plain, twill, leno or basket weave patterns are found to provide good performance. By using different strands as warp versus weft, a woven with anisotropic properties may be formed, reflecting for example typical properties of some natural tissue material like in leaflets of a heart valve. A woven fabric typically has a selvedge (or selvage) at its lengthwise edges, where the weft strands that run perpendicular to the edge of the structure are not extending from the structure as free ends but are continuous at the edge by returning into the woven structure. It will, however, be dependent on the actual use in and design of an implant whether such stable selvedge can remain and function as an edge, or whether a piece of textile of specific shape needs to be cut from a larger textile. It is for such latter situations that the present disclosure provides a method to make a (piece of) textile like a fabric having a stabilized cut edge; that is by using a certain laser for cutting through a polyurethane-coated part of the fabric, as further discussed hereinafter.

The composite biotextile comprises a textile that comprises, or has been made from, at least one strand with a titer of 2-250 dtex. The unit dtex or decitex is typically used in fiber industry, like the related unit denier, and indicates the linear density of a strand, fiber or yarn; with 1 dtex being 1 gram per 10.000 meter of strand. The lower the titer, the lower the thickness of a strand. A fabric made from thin strands will generally be thinner and more flexible or pliable than a textile made from thick strands, although the type of strand and type of polymer in a fiber, as well as textile type may also have some influence. In embodiments of the invention, the strands have a titer of at most 225, 200, 180, 160, 140, 120, 100, 80, 60 or 50 dtex; and of at least 4, 5, 6, 8, 10, 15, or 20 dtex. In embodiments, the at least one strand has a titer of 4-140, 6-100 or 8-60 dtex for a good balance between handleability, pliability, low profile, and strength of the fabric. The textile may comprise two or more strands, which may be of the same or different linear density. By using strands of different titer, thickness of the fabric may be varied in length and/or width direction to create local thickness or stiffness differences, or a certain texture, for example with a certain pattern depending on the type of fabric. The skilled person will be able to select strands of suitable titer depending on desired thickness and texture of the textile.

The composite biotextile comprises a textile that comprises at least one strand with a titer of 2-250 dtex and comprising fibers made from a biocompatible and biostable synthetic polymer. In embodiments, the textile contains at least 50 mass % of said strands, and the other strands may have different characteristics as long as the textile conforms to the other features as described herein. In preferred embodiments, the textile contains at least 60, 70, 80, 90, or 95 mass % of said strands, or is made from such strands.

In an embodiment, the textile provided has a thickness of about 15-300 μm. Thickness of the textile is related to the type of strands, the type of forming technique used in making the textile and density of the textile; that the distance between strands in the fabric. Preferably, the textile has a thickness of at most 275, 250, 225, 200, 175, 150, 125, 100, 90, or 80 μm for improved flexibility and pliability, and thickness of at least 20, 25, 30, 35, 40 45, or 50 μm for certain strength and durability properties. These values represent maximum and minimum thickness in case the textile has not a uniform thickness.

A strand in the textile may be of various different structures and be made from various biocompatible and biostable synthetic polymers. In embodiments, the at least one strand of the textile comprises at least one monofilament or multi-filament yarn. In case of a monofilament, a strand is preferably formed by one monofilament, typically with a titer of 2-50 dtex. If the monofilament is thicker, the stiffness of the textile may be too high for the intended application. Preferably, a monofilament has a titer of at most 45, 40, 35 or 30 dtex for a textile with good pliability.

In other embodiments, the at least one strand of the textile consists of one or more multi-filament yarns. Given above discussed dimensioning of strands, a multi-filament yarn in the textile can also have a titer of about 2-250 dtex. The yarn preferably has a titer of at most 225, 200, 180, 160, 140, 120, 100, 80, 60 or 50 dtex; and of at least 4, 5, 6, 8, 10, 15, or 20 dtex. In some embodiments, the at least one yarn has a titer of 4-120, 5-80, or 6-60 dtex. In case the strand comprises more than one yarn, titers are chosen to meet indicated ranges for a strand. The multi-filament yarn can be twisted or non-twisted. Twisted yarns generally are easier to handle and convert into a textile, whereas untwisted yarns may result in a more pliable textile, as filaments may move and shift easier relative to another and the cross-section of a yarn may have become more oblong or flattened in the textile. In some embodiments, the textile is made from strands that comprise non-twisted multi-filament yarn. This is for example advantageous in case of making UD constructs wherein filaments are preferably oriented in parallel. Typically, individual filaments contained in a multi-filament yarn may have a titer per filament that varies widely; like from 0.2 to 5 dtex or preferably 0.3-3 or 0.4-2 dtex per filament, and filaments can have a cross-section that is substantially round but also oblong or any other form.

The textile comprises at least one strand that is made from (or comprises) a biocompatible and biostable synthetic polymer. Suitable fibers have generally been made from a thermoplastic polymer, of which chemical composition may vary widely. Mechanical properties of the textile, especially strength and modulus, are preferably in ranges compatible with, or matching those of bodily tissues like ligaments, blood vessels, or valves. Biocompatible thermoplastic synthetic polymers that are used in fiber making include include materials like poly(meth)acrylates, polyolefins, vinyl polymers, fluoropolymers, polyesters, polyamides, polysulfones, polyacrylics, polyacetals, polyimides, polycarbonates, and polyurethanes, including copolymers, compounds and blends thereof. Such synthetic polymers may be based on natural compounds like amino acids and/or on synthetic monomers.

In embodiments, the biocompatible, biostable synthetic polymer is selected from polyolefins, polyketones, polyamides, and polyesters. Suitable polyolefins include polyethylenes and polypropylenes, especially such polymers of high molar mass like ultra-high molar mass polyethylene (UHMWPE). Suitable polyamides include aliphatic, semi-aromatic and aromatic polyamides, like polyamide 6, polyamide 66 and their copolymers, and poly(p-phenylene terephthalamide). Suitable polyesters include aliphatic, semi-aromatic and aromatic polyesters, like poly(l-lactic acid), polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polyethylene naphthalate (PEN), polyethylene furanoate (PEF), and liquid crystalline aromatic copolyesters. In an embodiment, the textile comprises strands of fibers made from PET or its copolymers. Polymer fibers can be made using different fiber spinning processes as known in the art; like solution spinning and melt spinning, including special techniques like gel spinning or electrospinning.

In embodiments, the strands in the textile have a tensile strength of at least 8 cN/dtex. Strength of a strand depends a.o. on the properties of the fibers in the strand. Therefore, the polymer fibers preferably have a tensile strength of at least 8 cN/dtex, or of at least 9 or 10 cN/dtex.

In further embodiments, the fibers in the strands have been made from one or more polyolefins selected from homopolymers and copolymers, including e.g. bipolymers, terpolymers, etc., containing one or more olefins such as ethylene and propylene as monomer units. Such polyolefins preferably have a high molar mass and may have been formed by any method known to those skilled in the art. A high molar mass is herein understood to mean a weight averaged molecular weight (or molar mass) of at least 350 kDa, as determined by GPC or as derived from solution viscosity measurements. Suitable examples of polyolefins include polypropylenes, polyethylenes, and their copolymers or blends; like polypropylene homopolymer, medium density polyethylene, linear or high-density polyethylene, copolymers of ethylene and relatively small amounts of one or more alpha-olefins such as butene-1, hexene-1, and octene-1, linear low-density polyethylene, ethylene/propylene copolymers, propylene/ethylene copolymers, polyisoprene and the like. Polypropylene and polyethylene polymers are preferred. An advantage of such high molar mass polyolefin fibers, in addition to their good biocompatibility and biostability, is the relatively high tensile strength such fibers may have; that is a tensile strength of at least 10 cN/dtex, which allows making thin yet strong and durable textiles.

In further embodiments, the strands in the textile comprise fibers made from a linear polyethylene such as a high molecular weight polyethylene (HMWPE) or an ultra-high molecular weight polyethylene (UHMWPE). The old term molecular weight is still interchangeably used in the art with molar mass; also reflected in the commonly used abbreviation for (ultra-)high molar mass polyethylene.

UHMWPE is a synthetic polymer that shows good biocompatibility in combination with high biostability or bio-inertness, and which is used in various biomedical devices and implants for quite some time already. UHMWPE is herein understood to be a polyethylene having an intrinsic viscosity (IV) of at least 4 dL/g, like between 4 and 40 dL/g. Intrinsic viscosity is a measure for molar mass that can more easily be determined than actual molar mass parameters like Mn and Mw. IV is determined according to method ASTM D1601(2004) at 135° C. on solution in decalin, the dissolution time being 16 hours, with butylhydroxytoluene as anti-oxidant in an amount of 2 g/L solution, by extrapolating the viscosity as measured at different concentrations to zero concentration. There are various empirical relations between IV and Mw, such relations typically being dependent on factors like molar mass distribution. Based on the equation Mw=5.37*10⁴ [IV]^(1.37) an IV of 8 dL/g would correspond to Mw of about 930 kDa, see EP0504954A1. In embodiments, the IV of the UHMWPE in the polyolefin film is at least 5, 6, 7 or 8 dL/g and IV is at most 30, 25, 20, 18, 16 or even at most 14 dL/g; to arrive at a balance between high mechanical properties and ease of processing. In general, the IV as measured on the UHMWPE polymer in a fiber or fabric can be somewhat lower than the IV of the polymer as used in making the fibers. During a fiber manufacturing process, like the gel-extrusion method described further on, the polyolefin may be subject to thermal, mechanical and/or chemical degradation, which may result in chain breakage, lowering of the molar mass and/or different molar mass distribution.

In further embodiments of the invention, the UHMWPE in the fibers may be a linear or slightly branched polymer, linear polyethylene being preferred. Linear polyethylene is herein understood to mean polyethylene with less than 1 side chain per 100 carbon atoms, and preferably with less than 1 side chain per 300 carbon atoms; a side chain or branch containing at least 10 carbon atoms. The linear polyethylene may further contain up to 5 mol % of one or more other alkenes that are copolymerizable with ethylene, e.g. C3-C12 alkenes like propene, 1-butene, 1-pentene, 4-methylpentene, 1-hexene and/or 1-octene. Side chains and comonomers in UHMWPE may suitably be measured by FTIR; for example on a 2 mm thick compression molded film, by quantifying the absorption at 1375 cm using a calibration curve based on NMR measurements (as in e.g. EP0269151).

The UHMWPE in the fibers may be a single polymer grade, but also a mixture of polyethylene grades that differ in e.g. molar mass (distribution), and/or type and amount of side chains or comonomer(s). The UHMWPE in the fibers may also be a blend with up to 25 mass % of another polyolefin as described above. Generally, the UHMWPE fibers are suitable for medical applications, containing only low amounts of customary and biocompatible additives and residual spin solvent. In embodiments the fibers contain at most 5, 4, 3 2 or 1 mass % of additives. In further embodiments the fibers contain at most 1000 ppm of spin solvent, preferably at most 500, 300, 200, 100 or 60 ppm.

In embodiments, the UHMWPE fibers comprised in strands of the textile have a tensile strength or tenacity of at least 15, 20, 25, 28, 30 cN/dtex and typically of at most about 40 cN/dtex, or at most 37 or 35 cN/dtex; and preferably a tensile modulus of at least 300 and up to 1500 cN/dtex. Tensile strength (or strength or tenacity) and tensile modulus (or modulus) of UHMWPE fibers are defined and determined at room temperature, i.e., about 20° C., for example on multifilament yarn as specified in ASTM D885M, using a nominal gauge length of the fibre of 500 mm, a crosshead speed of 50%/min and Instron 2714 clamps, of type “Fibre Grip D5618C”. Based on the measured stress-strain curve the modulus is determined as the gradient between 0.3 and 1% strain. For calculation of the modulus and strength, the tensile forces measured are divided by the titer, as determined by weighing 10 metres of yarns; values in cN/dtex are calculated assuming a density of 0.97 g/cm³.

In embodiments, the strands of the textile comprise at least 80 or 90 mass % of UHMWPE fibers or filaments with a tenacity of at least 15 cN/dtex. In other embodiments strands of the textile, for example the warp and/or the weft threads of a woven structure, substantially consist or consist of UHMWPE fibers or multi-filament yarn. In another embodiment, the warp strands (substantially) consist of UHMWPE and the weft strands (substantially) consist of another synthetic polymer like a polyester such as PET; alternatively weft strands consist of UHMWPE and warp strands of another polymer like PET. Such fabrics typically show anisotropic properties, like different strength and/or elongation in warp vs weft direction.

In embodiments, the high molar mass polyolefin fibers comprised in the textile have been made by a so-called gel-spinning process. In a typical gel-spinning process a solution of the polymer in a suitable spin solvent, optionally containing dissolved and/or dispersed further components, is spun and cooled into gel fibers that are subsequently drawn before, during and/or after partially or substantially removing the spin solvent. Gel spinning of a solution of UHMWPE is well known to the skilled person; and is described in numerous publications, including EP0205960A, EP0213208 A1, U.S. Pat. No. 4,413,110, GB2042414 A, EP0200547B1, EP 0472114 B1, WO2001/73173 A1, WO2015/066401A1, in Advanced Fiber Spinning Technology, Ed. T. Nakajima, Woodhead Publ. Ltd (1994), ISBN 1-855-73182-7, and in references cited therein. Examples of suitable UHMWPE multi-filaments yarns include those available as Dyneema Purity® grades (e.g. from DSM Biomedical BV, Sittard-Geleen NL).

Step b) of the present method concerns determining one or more locations on the textile where a cut is likely to be made in order to size or shape the textile for an intended use; which cutting would typically result in a non-stabilized edge when made in a non-modified textile such as a woven fabric, and which cut edge would likely show fraying or raveling during use, e.g. when a suture would be placed through the fabric near an edge and then tensioned. The skilled person may identify such locations on the textile for example as part of a development process of the textile for its intended use in or as a component of a medical device; which locations will depend on the design of the component and/or of the device, like a mesh, catheter balloon, vascular graft, stent-graft, occlusion device or prosthetic heart valve skirt or leaflet.

The method of present disclosure also comprises the optional step c) of pretreating the textile at least at the determined locations on at least one side of the textile with a high-energy source to activate the surface. Such treatment especially aims to improve bonding of the fibers to a polyurethane coating, but may simultaneously also clean the surface. Many synthetic polymer fibers, especially polyolefin fibers, have a non-polar and non-reactive surface, to which more polar polymers like polyurethanes may show little adhesion. Surface activation by for example a plasma or corona treatment is known, and may introduce functional groups, for example oxygen-containing groups. Suitable examples of plasma surface treatments include cold plasma treatments, which can be performed at atmospheric or reduced pressure and at a temperature that does not negatively affect the polymer fibers of the textile, for example with oxygen being present. In an embodiment the pretreatment step comprises atmospheric plasma activation. In an embodiment, the pretreatment step is performed to activate all surface of the textile, to allow providing the full textile surface, optionally impregnating the internal structure of the textile, with an adherent coating. The pretreatment step may not be needed, if the polymer fiber already shows sufficiently strong interaction with the polyurethane to be used; the skilled person will be able to assess this possibly assisted by some experiments. The inventors observed that for example in case of a textile made from a non-polar polymer like a polyolefin, the combination of surface pretreatment and applying a polyurethane having hydrophobic segments or endgroups as coating contributes to the favorable performance of the composite biotextile made.

The method of present disclosure also comprises a step d) of solution coating the textile at least at determined, and optionally pretreated, locations with a coating composition comprising a biocompatible and biostable polyurethane elastomer, a solvent for the polyurethane, and optionally auxiliary compounds. An elastomer is a polymeric material showing relatively low Young's modulus and better elastic recovery after elongation or deformation, when compared with other synthetic polymers, for example from which the fibers are made. A thermoplastic elastomer can be repeatedly molten by heating and re-solidified by cooling; and derives its elasticity from reversible physical cross-linking instead of from chemical cross-links as in thermoset elastomers. The polyurethane elastomer component used for making a composite biotextile may be thermoplastic or form a thermoset during or after the coating step; but the polyurethane is soluble in a suitable solvent. An advantage thereof vs melt coating is that a polyurethane solution of relatively low viscosity can be used to coat, within present context this includes to optionally impregnate, the textile at a temperature well below the relaxation, softening or melting temperature of the polymer of the fibers. Coating at low temperature prevents deteriorating fiber and textile properties by partial melting; considering that the melting point of a polymer like a polyolefin may be below the melting point of a thermoplastic polyurethane elastomer (TPU). Use of a solution of a polyurethane elastomer or a TPU to coat the textile also has the advantage that by choosing conditions and solution viscosity a coating layer may be formed predominantly on the surface of the textile, but the solution may also be made to penetrate between strands and fibers and to partially or even fully cover the fibers and impregnate the fabric. A coated textile wherein strands or fibers are locally or substantially fully covered or embedded by polyurethane can also be called an impregnated fabric. Such coated (or impregnated) textile may have several properties distinct from the starting textile, like reduced gas and/or liquid permeabilities, and surface properties will be much like those of the polyurethane. In case only one side of the textile is coated with polyurethane with no or limited penetration between fibers, surface properties of only one side of the textile will be changed, and the non-coated side may stay substantially unchanged; except for e.g. permeability of the textile. Sides of such composite biotextile may for example show different interactions with biological matter; for example the coated side may show good blood compatibility without causing clotting, whereas at the non-coated side having more surface texture and/or porosity ingrowth of tissue may occur when used as a graft material. A coating of polyurethane may be applied on all surface area of the textile, but also only locally at selected parts of the surface, and on one or both sides of the textile.

Polyurethane elastomers are typically block copolymers (also called segmented copolymers). Block copolymers are polymers comprising blocks (also called segments) of polymers (including oligomers) that are chemically distinct, and which show different thermal and mechanical properties, and different solubilities. Often the blocks in a block copolymer comprising two (or more) types of blocks are referred to as being ‘hard’ and ‘soft’ polymer blocks, such different blocks resulting in microphase separation of hard and soft blocks. The hard block in a block copolymer typically comprises a rigid or high modulus polymer, with a melting temperature (T_(m)) or a glass transition temperature (T_(g)) higher than the use temperature, of e.g. about 35° C. The soft block in the block copolymer often comprises a flexible, low modulus, amorphous polymer with a T_(g) lower than 25° C., preferably lower than 0° C. As for most mechanical properties, thermal parameters like T_(m) and T_(g) are generally determined on dry samples; using well-known techniques like DSC or DMA. In such phase-separated block copolymers, the hard segments function as physical crosslinks for the flexible soft segments, resulting in materials having properties ranging from fairly stiff to flexible and elastic, depending on the ratio of hard to soft blocks. Depending on type and amount of hard blocks, the polyurethane may show good stability and elasticity over a desired temperature range without the need for chemical crosslinking; and can generally be processed as a thermoplastic. The term thermoplastic polyurethane elastomer basically denotes a family of polymers with a substantially linear backbone comprising the reaction product of at least three principle components; that are a diisocyanate, a diol chain extender and a polymer diol or macroglycol. Optionally, a monofunctional compound may be used as a further component functioning as a chain stopper and forming endgroups, like non-polar or hydrophobic endgroups. In embodiments, the backbone of the polyurethane elastomer or the TPU applied in present invention is linear and has one or an average of two hydrophobic endgroups.

In embodiments, the polyurethane elastomer comprises hard blocks that include urethane groups and optionally urea groups in repeating units, which have resulted from reaction of a diisocyanate with a diol and optionally a diamine as chain extender.

Suitable diisocyanates include aromatic, aliphatic and cycloaliphatic compounds, having an average of 1.9-2.1 isocyanate groups per molecule. In an embodiment, the diisocyanate comprises 4,4′-diphenylmethane diisocyanate (MDI), 2,4-toluene diisocyanate, 2,6-toluene diisocyanate (TDI), 1,4-phenylene diisocyanate, hexamethylene diisocyanate (HDI), tetramethylene-1,4-diisocyanate, cyclohexane-1,4-diisocyanate, dicyclohexylmethane-4,4′-diisocyanate (HMDI), isophorone diisocyanate (IPDI), or a mixture thereof. In an embodiment, the diisocyanate comprises hexamethylene diisocyanate, dicyclohexylmethane 4,4′-diisocyanate, isophorone diisocyanate, or a mixture thereof. In an embodiment, the diisocyanate consists of hexamethylene diisocyanate, dicyclohexylmethane 4,4′-diisocyanate, isophorone diisocyanate, or a mixture thereof. In an embodiment, the diisocyanate comprises 4,4′-diphenylmethane diisocyanate, 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, or 1,4-phenylene diisocyanate. In an embodiment, the diisocyanate consists of 4,4′-diphenylmethane diisocyanate, 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, 1,4-phenylene diisocyanate, or a mixture thereof. In an embodiment, the molar mass of the diisocyanate is from 100 to 500 g/mol. In an embodiment, the molar mass of the diisocyanate is from 150 to 260 g/mol.

Chain extenders are typically low molar mass aliphatic compounds, having two or more hydroxyl or amine groups. Bifunctional chain extenders result in linear, generally thermoplastic polymers, whereas multifunctional isocyanates and/or chain extenders would lead to branched or cross-linked products. In an embodiment, the bifunctional chain extender has a molar mass of at least 60 g/mol, at least 70 g/mol, at least 80 g/mol, at least 90 g/mol, or at least 100 g/mol. In an embodiment, the chain extender has a molar mass of at most 500 g/mol, at most from 400 g/mol, at most 300 g/mol, at most 200 g/mol, or at most 150 g/mol. In an embodiment, the chain extender comprises ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, or 1,8-octanediol; and/or such corresponding diamines. In embodiments, the polyurethane elastomer comprises only diol chain extenders and shows thermoplastic behavior; that is the polyurethane elastomer is a thermoplastic polyurethane elastomer or TPU.

In other embodiments, the polyurethane elastomer comprises hard blocks having both urethane and urea linkages. The advantage thereof is enhanced interaction between the hard blocks, allowing a higher content of soft blocks resulting in block copolymers showing enhanced flexibility and elasticity, and excellent flex life or fatigue resistance. Depending on the ratio diol/diamine, the polyurethane elastomer may show such strong interaction that at a melt processing temperature thermal degradation may be such that solution processing is to be preferred for optimal performance. Commercially available examples of such polyurethane elastomers comprising both urethane and urea linkages include Biospan® products (available from e.g. DSM Biomedical BV, Sittard-Geleen NL).

In further embodiments, the polyurethane elastomer comprises soft blocks derived from at least one aliphatic polymer diol or polyol, which is chosen from the group consisting of polyethers, polyesters, polyacrylates, polyolefins and polysiloxanes (also called silicones); which polymers are bifunctional with hydroxyl (or amine) terminal groups. Such polymer diols for the soft blocks are understood herein to include oligomers, homopolymers and copolymers, and polyesters are considered to include polycarbonates. Generally known polyurethane block copolymers and methods to prepare these copolymers are described in a.o. U.S. Pat. Nos. 4,739,013, 4,810,749, 5,133,742 and 5,229,431.

In embodiments of the present disclosure the polyurethane elastomer comprises as soft block at least one polymer diol chosen from an aliphatic polyester diol, an aliphatic polyether diol, a poly(isobutylene) diol and a polysiloxane diol. As for chain extenders, also amine-functional soft blocks can be used, resulting in additional urea linkages. Biocompatibility and biostability of such polyurethane block copolymers in the human body has been proven.

Mechanical and other properties of a polyurethane block copolymer can be tailored by varying chemical compositions and/or molar mass of the blocks. The hard blocks of a polyurethane elastomer for use in the invention may have a molar mass of about 160 to 10,000 Da, and more preferably of about 200 to 2,000 Da. The molar mass of the soft segments may be typically about 200 to 100,000 Da, and preferably at least about 400, 600, 800 or 1000 Da and at most about 10,000, 7500, 5000, 4000, 3000 or 2500 Da. Within the context of present disclosure, molar mass of polymers and oligomers discussed refers to the number average molar mass (Me), as for example derived from GPC measurements. The ratio of soft to hard blocks can be chosen to result in certain stiffness or hardness of the polymer. Typically, hardness of the polyurethane as measured with the Shore durometer hardness test using A or D scales, may be from 40 ShA, or at least 50 or 60 ShA and up to 80, 75, 70, 65 or 60 ShD or up to 100, 90 or 85 ShA, generally representing a flexural modulus range of about 10 to 2000 MPa. In embodiments, the polyurethane elastomer has a hardness from 40 ShA to 60 ShD, preferably 40-100 ShA or 40-90 ShA.

In further embodiments of present invention, the polyurethane elastomer comprises an aliphatic polyether or an aliphatic polyester as soft block, more specifically an aliphatic polycarbonate. Suitable aliphatic polyethers include poly(propylene oxide) diols, poly(tetramethylene oxide) diols, and their copolymers. Suitable aliphatic polyesters are generally made from at least one aliphatic dicarboxylic acid and at least one aliphatic diol, which components are preferably chosen such that an essentially amorphous oligomer or polymer is formed having a T_(g) below 10, 0, or −10° C. Aliphatic polycarbonate diols are based on similar aliphatic diols as used for polyester diols, and can be synthesized via different routes as known in the art. Suitable examples include poly(hexamethylene carbonate) diols and poly(polytetrahydrofuran carbonate) diols. In an embodiment, the soft block is based on a poly(hexamethylene carbonate) diol, a poly(polytetrahydrofuran carbonate) diol, or a mixture thereof.

In a further embodiment, the soft block comprises a polysiloxane diol such as a poly(dimethyl siloxane) diol, a polycarbonate diol, or a poly(tetramethylene oxide) diol. In an embodiment, the soft block is based on a polysiloxane diol, a polycarbonate diol, a poly(tetramethylene oxide) diol, or a mixture thereof. In an embodiment, the soft block comprises a mixture of two or more of a polysiloxane diol, a polycarbonate diol, or a poly(tetramethylene oxide) diol. In an embodiment, the soft block is based on a mixture of two or more of a polysiloxane diol, a polycarbonate diol, or a poly(tetramethylene oxide) diol. In an embodiment, the soft block comprises a polysiloxane diol and one or more of a polycarbonate diol and a poly(tetramethylene oxide) diol. In an embodiment, the soft block is based on a polysiloxane diol and one or more of a polycarbonate diol and a poly(tetramethylene oxide) diol.

In an embodiment, the soft blocks may further comprise a C₂-C₁₆ fluoroalkyl diol or C₂-C₁₆ fluoroalkyl ether diol. In an embodiment, the soft block in the polyurethane backbone comprises the residue of 1H,1H,4H,4H-Perfluoro-1,4-butanediol, 1H,1H,5H,5H-Perfluoro-1,5-pentanediol, 1H,1H,6H,6H-perfluoro-1,6-hexanediol, 1H,1H,8H,8H-Perfluoro-1,8-octanediol, 1H,1H,9H,9H-Perfluoro-1,9-nonanediol, 1H,1H,10H,10H-Perfluoro-1,10-decanediol, 1H,1H,12H,12H-Perfluoro-1,12-dodecanediol, 1H,1H,8H,8H-Perfluoro-3,6-dioxaoctan-1,8-diol, 1H,1H,11H,11H-Perfluoro-3,6,9-trioxaundecan-1,11-diol. fluorinated triethylene glycol, or fluorinated tetraethylene glycol.

In an embodiment, the C₂-C₁₆ fluoroalkyl diol or C₂-C₁₆ fluoroalkyl ether diol has an M_(n) of at least 150 g/mol, at least 250 g/mol, or at least 500 g/mol. In an embodiment, the fluoroalkyl diol or fluoroalkyl ether diol has a molar mass of at most 1500 g/mol, at most 1000 g/mol, or at most 850 g/mol. In an embodiment, the C₂-C₁₆ fluoroalkyl diol or C₂-C₁₆ fluoroalkyl ether diol is present in an amount of at least 1 mass %, at least 2 mass %, or at least 5 mass %, based on the total mass of the polyurethane. In an embodiment, the C₂-C₁₆fluoroalkyl diol or C₂-C₁₆ fluoroalkyl ether diol is present in an amount of at most 15 mass %, at most 10 mass %, or at most 8 mass %, based on the total mass of the polyurethane.

In embodiments, the polyurethane elastomer may comprise one or more hydrophobic endgroups. An endgroup is a generally a non-reactive moiety present at a terminal end of a molecule. In an embodiment, the polyurethane elastomer is linear and comprises a hydropobic endgroup at one end or terminus, preferably at each terminus of the backbone; i.e. it has an average of about 2 endgroups. In an embodiment, the hydrophobic endgroup is a linear compound. In another embodiment, the hydrophobic endgroup is branched. An endgroup may have been formed by reacting a terminal isocyanate group present during or after forming the polymer backbone with a co-reactive group on a monofunctional compound, also called chain stopper. For instance, a formulation for forming a polyurethane may comprise a diisocyanate, a polymeric aliphatic diol, a chain extender, and a monofunctional alcohol or amine; like 1-octanol or octylamine to form a C₈ alkyl endgroup.

In an embodiment, the hydrophobic endgroup comprises a C₂-C₂₀ alkyl, a C₂-C₁₆ fluoroalkyl, a C₂-C₁₆ fluoroalkyl ether, a hydrophobic poly(alkylene oxide) or a polysiloxane, including copolymers thereof. In an embodiment, the hydrophobic poly(alkylene oxide) is poly(propylene oxide), poly(tetramethylene oxide) or a copolymer thereof. In an embodiment, the hydrophobic endgroup is a polysiloxane, like a poly(dimethyl siloxane). In an embodiment, the endgroup comprises C₂-C₂₀ alkyl, C₂-C₁₆ fluoroalkyl, C₂-C₁₆ fluoroalkyl ether, or a hydrophobic poly(alkylene oxide). Such endgroups may be formed with monofunctional alcohols, including carbinols, or amines of the foregoing. Such polyurethane elastomers having hydrophobic endgroups are found to positively affect properties of the polyurethane and its interaction with other materials, including other polymers like polyolefins and bodily tissue and fluid like blood.

In an embodiment, the hydrophobic endgroup comprises C₂-C₁₆ fluoroalkyl or C₂-C₁₆ fluoroalkyl ether. Such endgroups may be formed with monofunctional alcohols or amines comprising C₂-C₁₆ fluoroalkyl or C₂-C₁₆ fluoroalkyl ether. In an embodiment, the endgroup is formed from 1H,1H-Perfluoro-3,6-dioxaheptan-1-ol, 1H, 1H-Nonafluoro-1-pentanol, 1H,1H-Perfluoro-1-hexyl alcohol, 1H,1H-Perfluoro-3,6,9-trioxadecan-1-ol, 1H,1H-Perfluoro-1-heptyl alcohol, 1H,1H-Perfluoro-3,6-dioxadecan-1-ol, 1H,1H-Perfluoro-1-octyl alcohol, 1H,1H-Perfluoro-1-nonyl alcohol, 1H,1H-Perfluoro-3,6,9-trioxatridecan-1-ol, 1H,1H-Perfluoro-1-decyl alcohol, 1H,1H-Perfluoro-1-undecyl alcohol, 1H,1H-Perfluoro-1-lauryl alcohol, 1H,1H-Perfluoro-1-myristyl alcohol, or 1H,1H-Perfluoro-1-palmityl alcohol.

In an embodiment, the hydrophobic endgroup is monomeric and has a molar mass of 200 g/mol or more, 300 g/mol or more, or 500 g/mol or more; and of 1,000 g/mol or less or 800 g/mol or less. In an embodiment, the endgroup is polymeric and has a molar mass of 10,000 g/mol or less, 8,000 g/mol or less, 6,000 g/mol or less, or 4,000 g/mol or less. In an embodiment, the endgroup is polymeric and has a molar mass of 500 g/mol or more, 1,000 g/mol or more, or 2,000 g/mol or more.

In an embodiment, the hydrophobic endgroup is present in an amount of at least 0.1 mass %, at least 0.2 mass %, at least 0.3 mass %, or at least 0.5 mass %, based on the total mass of the polyurethane. In an embodiment, the hydrophobic endgroup is present in an amount of at most 3 mass %, at most 2 mass % or at most 1 mass %, based on the total mass of the polyurethane. In an embodiment, the hydrophobic endgroup is present in an amount of at least 0.1 mass %, at least 0.2 mass %, at least 0.3 mass %, or at least 0.5 mass %; and in an amount of at most 3 mass %, at most 2 mass % or at most 1 mass %, based on the total mass of the polyurethane.

The hard blocks in such polyurethane or TPU are typically based on an aromatic diisocyanate like toluene diisocyanate (TDI) or methylenediphenyl diisocyanate (MDI), and a low molar mass aliphatic diol like 1,4-butanediol. Polyether and polycarbonate polyurethanes may be suitably used for biomedical applications, in view of their flexibility, strength, biostability, biocompatibility and wear resistance. A TPU containing a combination of a polyether and a polysiloxane or a polycarbonate and a polysiloxane for example in the soft blocks shows a unique combination of properties and may advantageously be used as the polyurethane in the coating composition. Commercially available examples of such polymers include Carbosil® TSPCU products (available from DSM Biomedical BV, Sittard-Geleen NL).

In a further embodiment, the polyurethane or TPU may be a blend of two or more polymers. In other embodiments the polyurethane or TPU may comprise one or more customary additives that are allowed for the targeted use of the composite biotextile; in addition to e.g. catalyst residues. Examples of additives include stabilizers, anti-oxidants, processing aids, lubricants, surfactants, antistatic agents, colorants, and fillers. The additives may be present in the typically effective amounts as known in the art, such as 0.01-5 mass % based on the amount of the polyurethane, preferably 0.01-1 mass %. In another embodiment, the polyurethane or TPU substantially consists of polymer, and is substantially free of additives.

In embodiments, the composite biotextile comprises a textile comprising polymer fibers and a coating comprising a biocompatible and biostable TPU, wherein the TPU may show at a temperature above its melting point a melt flow that is at least 10 times higher than the melt flow of the polymer. A TPU may have a melting point that is higher than the melting point of the polymer, for example a polyolefin that may melt in a range 130-190° C. (a.o. depending on amount of oriented crystals present; for example in high-strength UHMWPE fibers, which show multiple melting in a range 130-155° C.). Basically, this melt flow feature specifies that the melt viscosity of the polymer, e.g. polyolefin, at a certain temperature above the melting points of polymer and of TPU, for example at temperature that may locally be reached during laser cutting, is significantly higher than the melt viscosity of the TPU, such that molten polymer shows substantially no melt flow whereas the molten TPU may flow in the textile or around fibers of the textile. Melt flow is typically measured as melt flow rate (MFR; also called melt flow index, MFI) following ASTM D1238 standard and reported as the amount of polymer extruded during a fixed while (that is in g/10 min) from a certain opening under a certain weight and at a certain temperature as specified for different polymers in the standard. High molar mass polyolefins, like HMWPE, typically have such high melt viscosity that a high mass is used in the test (21.6 kg vs 2.16 kg for most polymers) to have a measurable result (e.g. 0.2-1 g/10 min at 190° C. and 21.6 kg). UHMWPE grades typically have such high viscosity that there is no measurable melt flow under such conditions. In embodiments, the TPU has at said temperature above its melting point, for example at 210-240° C., a melt flow rate that is at least 10, 20, 40, 60 or even 100 times the melt flow rate of the polymer, e.g. a polyolefin like a UHMWPE. In case of fibers made from a polymer that does not melt up to a temperature of 250° C. or higher, TPU may similarly flow around fibers at the edge during laser cutting. The laser cut itself is likely resulting from very local heating of textile fibers and coating to such temperature that material degrades and evaporates by focused laser energy.

Polyurethanes typically may absorb moisture from the environment like up to several mass %, and are preferably dried before dissolving in solvent, optionally at elevated temperature, under an inert gas flow or under reduced pressure e.g. to a level of less than 0.05 mass %. Such drying process is known to a skilled person.

The coating composition applied in the present method further comprises a solvent for the polyurethane. A suitable solvent for polyurethane can substantially, or preferably homogeneously dissolve the polyurethane; but the polymer of the fibers is not dissolved in the solvent, at least not under the conditions of performing the present method. The person skilled in the art will be able to select a suitable solvent for a given polyurethane and polymer combination based on his general knowledge, optionally supported by some literature; for example based on solubility parameters of solvents and polymers, like given in the “Polymer Handbook” by Brandrup and Immergut, Eds. The skilled person is also aware of effects of polymer molar mass on solubility. For a so-called good solvent for a polyurethane including a TPU, interactions between polymer chain and solvent molecules are energetically favorable, and difference between solubility parameters of polymer and solvent is small. In present case of finding a solvent for the polyurethane that is a non-solvent for the polymer, the skilled person may also perform some dissolution experiments, including stirring or sonication and optionally by applying some heating.

In embodiments of the method, the solvent may be tetrahydrofuran (THF), methyl-tetrahydrofuran (m-THF), dimethylformamide (DMF), dimethylacetamide (DMAc), dimethylsulfoxide (DMSO), dichloromethane, chloroform, hexafluoro isopropanol, dioxane, dioxolane, mixtures thereof, or mixtures thereof with other less good solvents (or co-solvent), provided such mixtures can dissolve the polyurethane. In view of removing the solvent after application from the film, a solvent having such volatility that solvent can be substantially removed by evaporation, optionally by heating to a temperature at least 10° C. below the melting point of the polymer and polyurethane, is preferred. In an embodiment, THF or m-THF is the solvent, preferably THF is the solvent.

The concentration of polyurethane in the solution applied in the solution coating step is not critical and will generally be in the range of 0.1-20 mass % of polyurethane in solution. It was observed in experiments, however, that if penetration of solution in voids or pores between strands or fibers of the textile, i.e. impregnation of the textile, is desired a solution of relatively low viscosity is preferably used. On the other hand, the higher the polyurethane concentration the less solution needs to be applied for effective coating while limiting impregnation. In embodiments, the solution of elastomer may have a Brookfield viscosity of about 1-5000 mPa·s, or a viscosity of at least 5, 10, 25 or 50 mPa·s and at most 3000, 2000, 1000, or 500 mPa·s. Optimizing biological interactions of the composite biotextile can thus be done by varying coating conditions and locally or partially coating versus fully coating and optionally impregnating the textile.

The coating composition may further contain one or more auxiliary compounds, like, antibiotics, pharmacological agents to inhibit graft (re-)stenosis (e.g., Paclitaxel), or other biologics and small molecules to illicit a desired biological response, or radiopacifying agents. Such optional auxiliary compounds preferably have been approved for the targeted application by regulatory bodies like FDA; and may typically be present in relatively small, effective amounts, such that their concentration in the composite biotextile is effective for its purpose and within approved ranges, yet without unacceptably deteriorating other performance properties of the composite biotextile.

In other embodiments, the coating composition further comprises a radiopacifier as additive, typically at a relatively high amount like 15-80 mass % based on polyurethane for effective visualization of the composite textile with medical imaging techniques using x-rays or other radiation. In an embodiment, the radiopacifier comprises tantalum, gold, platinum, tungsten, iridium, platinum-tungsten, platinum-iridium, palladium, rhodium, barium sulfate, bismuth subcarbonate, bismuth oxychloride, bismuth trioxide, ionic or non-ionic contrasting agents such as diatrizoates, iodipamide, iohexyl, iopamidol, iothalamate, ioversol, ioxaglate, and metrizamide, or a combination thereof. In an embodiment, the radiopacifier comprises tantalum, gold, platinum, tungsten, or a mixture or alloy thereof. In an embodiment, the radiopacifier is present as particles dispersed in the coating composition, for example made by dispersing particles in a solution of polyurethane. In an embodiment, the radiopacifier particles have an average particle diameter of at least 1 nm, preferably at least 5, 10, 25, 50, 100, or 200 nm. In an embodiment, the radiopacifier particles have an average particle diameter of at most 3 μm, preferably at most 2, 1, 0.5, or 0.2 μm. Average particle diameter is measured using photon correlation spectroscopy (PCS) in accordance with ISO13321:1996. In an embodiment, the radiopacifier is surface treated with an adhesion promoter to enhance adhesion to the polyurethane; like with a glycidyl methacrylate (GMA) modified random ethylene/acrylate copolymer, or a GMA and maleic anhydride (MA) modified random ethylene/acrylate copolymer. In an embodiment, the radiopacifier is present in the coating composition in an amount of at least 20, 30, 40, or 50 mass %; and of at most 75, 70, 65, 60 or 55 mass % as based on polyurethane.

Solution coating as such is well known to a skilled person, and can be performed using various application techniques, like using a pipette or a syringe, dip-coating, spray coating, ink jet application, and the like; from which the skilled person can select the method most suitable for an actual situation based on common knowledge and some routine testing. The textile may be partially coated, to form one or more stripes or any other pattern, or fully coated and impregnated; as is further described below for the composite biotextile as obtained. The coating composition may be applied in one step, but also in multiple steps applying e.g. smaller amounts, for example with certain time between steps to allow the solution to at least partially dry.

The method of present disclosure also comprises a step e) of removing the solvent from the coated textile, preferably the solvent is substantially removed. A simple and preferred way is to evaporate the solvent (or solvent mixture). This may be performed at ambient conditions, but also by applying a reduced pressure and/or an elevated temperature to enhance efficiency. If an increased temperature is used, care should be taken to prevent deterioration of properties of the composite biotextile, for example caused by partial melting and/or stress relaxations of the polymer fibers in the textile. Preferably, the temperature applied remains well, for example at least 10° C., below the melting temperature of the polyurethane or TPU and of the polymer. Optionally, or alternatively, a washing step is applied to substantially remove the solvent. Washing can be done with a liquid comprising or consisting of a wash solvent that is a non-solvent for both the polyurethane and the polymer but is miscible with the solvent for the polyurethane. Such washing step can be performed at ambient temperature, but also at elevated temperature with similar constraints as indicated above. Solvent removal is typically performed to result in a residual solvent level of the composite biotextile that is in accordance with specifications or regulations for use in a medical implant. In an embodiment, the composite biotextile has a residual solvent content of less than 50 ppm; for example after drying under nitrogen for 24 hours followed by drying in a convection oven at 50° C. for one hour.

In embodiments of the method, the textile may be mounted in a holder or frame to keep the textile in its form, e.g. even and flat, without notably tensioning the strands of the textile, and then be subjected to one or more of the steps of pretreating, solution coating and removing solvent. Advantages hereof may include more evenly pretreating and coating the textile, as well as preventing shrinkage, or deforming like wrinkling during e.g. coating and solvent removing steps. The skilled person will be able to select a suitable frame or alternative method of preventing the textile from deforming without hindering for example effectively coating at desired locations.

These above steps of the method result in a composite biotextile wherein polyurethane is present in an amount of 2.5-90 mass % based on composite biotextile, as further described below.

The method of present disclosure further comprises a step f) of cutting the composite biotextile as obtained at one or more coated locations with an ultra-short pulse laser, which prevents over-heating and deformation of the cut edge but may induce a local temperature above the melting point of polyurethane, to form a piece of composite biotextile of a desired size and/or shape, and having at least one laser-cut edge where polyurethane coating is present; that is having at least one stabilized cut edge. The skilled person will be able to select a suitable laser and settings for cutting the coated or composite biotextile, to make a well-defined neat cut in the textile while preventing damage or other irregularities caused by local overheating. Ultra-short pulse (USP) lasers are known in the art, and include nano-, pico- or femtosecond pulsed lasers. In embodiments, a cut is made with an USP laser applying an energy level setting of about 10-26 W, preferably 12-24, 14-22 or 16-20 W. In embodiments, a cut is made applying a cutting speed of 1-12 mm/s, preferably 2-10 or 3-8 mm/s. More than one scan with the USP laser may be needed to cut completely through the composite biotextile, o.a. depending on its thickness. In order to prevent damage to the biotextile, multi-step cutting may be preferred over using higher energy settings.

Other aspects of the invention relate to a composite biotextile for use in or as a medical implant component, and to a medical implant component comprising a composite biotextile as obtained with or by the method as described above, including the various features and embodiments described hereinabove, and which features may be present in any combination, unless a skilled person finds such combination technically not feasible.

Basically, the invention provides a piece of composite biotextile as described above for the method of making, which biotextile has at least one cut edge that is coated (and/or impregnated) with polyurethane elastomer, i.e. the biotextile has a stable or stabilized cut edge which is not a (woven) selvage. Such cut edge typically is the result of cutting a coated textile with a pulsed laser at a location where polyurethane coating was applied as described above.

In a preferred embodiment, the composite biotextile comprises a textile made from at least one strand having titer of 2-250 dtex and comprising fibers made from UHMWPE and a coating comprising a biocompatible and biostable polyurethane elastomer, wherein polyurethane is present in an amount of 2.5-90 mass % based on composite biotextile and at least at a cut edge, wherein the composite biotextile has a suture retention strength at the cut edge of at least 15 N, as measured with the method described in the experiments. In further embodiments, the composite biotextile shows a suture retention strength of at least 20, 22 or 24 N; whereas such strength may be at most about 50, 45 or 40 N.

The composite biotextile comprises a textile and a coating comprising a biocompatible and biostable polyurethane elastomer in an amount of 2.5-90 mass % based on composite biotextile, wherein the polyurethane coating is present on at least part of the surface of at least one side of the biotextile. In embodiments, the polyurethane coating is present on substantially all surface area of both sides of the textile. Such composite biotextile can for example have been made by dip-coating the textile by immersing in a solution of the polyurethane and subsequently removing the solvent. The thickness of the coating layer can be adjusted by varying the concentration of polyurethane in the solution or by varying the pick-up speed of removing the textile from the solution. Depending on said conditions and on the thickness and packing density of strands in the textile, that is on how much space there is available as e.g. pores between strands and individual fibers in the textile, the polyurethane can be present in the composite biotextile merely as a surface coating, but the polyurethane may also have impregnated or embedded the strands and fibers in the textile. In such latter case, the composite biotextile could also be referred to as a textile-reinforced or fiber-reinforced polyurethane. Anyhow, such fully coated composite biotextile will show several different properties compared to the non-coated textile, depending on the type and amount of polyurethane coating. An advantage of such composite biotextile is that it can be cut using a laser at any location on the composite biotextile, to make a piece of textile of desired shape and having a stabilized cut edge showing improved fraying resistance and suture retention strength versus non-coated textile. A suitable laser for such purpose is selected and applied with such settings that enough energy is provided at the location to make a cut through the composite textile, whereby optionally a local temperature adjacent to the cut being made may be reached that is above the melting point of the polyurethane, especially a TPU; such that the TPU locally may form a melt that flows to connect cut fiber ends with each other and/or with other fibers in the textile. On the other hand, laser settings are selected such that no excessive heating occurs, because in such case an irregular and deformed or disrupted cut edge may result in the textile. Such overheated edge may also show undesirable stiffening at the edge zone, deteriorating textile pliability. The skilled person will be able to select a laser suitable for said purpose, like a CO₂, Nd or Nd-YAG laser, and to select proper settings including controlling the energy of the beam by e.g. pulsing frequency and cutting speed. Generally, a CO₂ laser can be suitably used for cutting the composite biotextile. It has been found, however, that when using a continuous mode (or wave) laser excessive heat-transfer to the composite biotextile may occur, thereby distorting the cut edge or causing partial melting or shrinkage of the polymer (like UHMWPE) textile due to e.g. thermal relaxation effects of oriented crystals in the fibers. Therefore, a pulsed laser is applied; that is a laser that emits light not in a continuous mode, but rather in the form of optical pulses. More specifically, short pulse or ultra-short pulse lasers, like nano-, pico-, or femtosecond pulse lasers, are applied in present method as they do not excessively heat the composite biotextile to cause morphological distortion adjacent the cut, while polyurethane may still melt to secure the cut edge.

In other embodiments, the polyurethane elastomer coating is present on part of the surface area of both sides of the textile. The polyurethane can for example be present as one or more stripes, that is as an elongated coated and/or impregnated area or section of the textile with a width of at most 10 mm. Such stripe may for example have been formed from an array of adjacently or partly overlapping applied polyurethane solution droplets such as by using a (micro-) pipette, spray coating or an ink jet printing device. The coating composition comprising polyurethane may have been applied to both sides of the textile at opposing and corresponding places, or at one side only; to basically surface coat the textile, or to partially impregnate the textile like in case of a textile into which the applied solution will penetrate across its thickness. A stripe can also result from a dip-coating process wherein the textile is only partly submerged in polyurethane solution at one or more of its edges, especially if merely a coating at an edge zone of the textile is desired. In embodiments, the stripes of polyurethane coating have a width of at most 8, 6, 5, or 4 mm. Minimum width of stripe may be as small as 1 mm, or at least 2 or 3 mm for effectively increasing suture retention and/or fraying resistance. The stripes are at least positioned on those places or areas of the textile, where for an intended use of the textile a laser cut is to be made to further size and shape the textile. Polyurethane coating may also have been applied at other locations of the textile to change other properties of the textile. The skilled person will be able to identify such locations, for example while reviewing performance requirements of an intended use of the textile; by reviewing literature, by computer aided designing and modelling, or by performing tests including failure analysis on existing devices and/or on prototypes.

In further embodiments, the polyurethane coating is present on part of the surface of one side of the textile. Stripes of polyurethane can have been applied by using spray coating or ink jet coating, similarly as described above. In other embodiments, the polyurethane coating is present on substantially all surface area of one side of the textile. A one-side polyurethane-coated composite biotextile, for example a relatively dense textile like a woven fabric that was coated by using solvent casting, spray or ink jet coating, may be advantageously used in biomedical applications wherein a relatively smooth, coated surface of the textile is in contact with blood and the non-coated textile faces tissue; for example as in a stent-graft wherein the graft material combines good blood compatibility on the inside with tissue in-growth on the outside, and showing suitable suture retention strength for attachment to the stent frame.

In still further embodiments, the polyurethane coating is present on part of the surface area of one side and on substantially all surface area of the other side of the textile.

The composite biotextile comprises a textile and a coating comprising a biocompatible and biostable polyurethane elastomer, wherein the polyurethane is present in an amount of 2.5-90 mass % of the composite biotextile. Such amount will depend a.o. on the relative surface area of the textile that is coated (and optionally impregnated) and on porosity of the textile. In embodiments, polyurethane is present in an amount of at least 5, 10, 15, 20 or 25 mass %, and of at most 80, 70, 60, 50, 40 or 30 mass %. Lower amounts of polyurethane coating relate typically to a composite biotextile that is partially coated on one side, whereas the higher ranges may relate to substantially fully and two-sided coated composite biotextiles, which might also be referred to as textile-reinforced polyurethanes.

In other embodiments, the amount of polyurethane in the composite textile may be expressed in the amount per surface area or areal density; such as an amount of 0.2-10 mg/cm² based on composite textile, or at least 0.5, 1.0, 1.5, 2.0 or 2.5 mg/cm² and at most 9, 8, 7, 6, or 5 mg/cm², depending on factors as discussed above.

In an embodiment, the composite biotextile has a thickness of about 15-350 μm. Thickness of the composite biotextile is related to the type of strands, the type of forming technique used in making the textile and density of the textile; and related to the amount of polyurethane, and whether polyurethane is on the surface of the textile and/or between strands in the textile. In embodiments, the composite biotextile has a thickness of at most 325, 300, 275, 250, 225, 200, 175, 150, 125, 100, 90, or 80 μm for improved flexibility and pliability, and thickness of at least 20, 25, 30, 35, 40 45, or 50 μm for certain strength and durability properties.

In still further aspects, the invention concerns the use of said composite biotextile having a stabilized laser-cut edge, in a medical implant component or as a medical implant component, especially for applications wherein the textile will be in contact with body tissue or fluids, such as in orthopedic or cardiovascular applications; like a mesh, a vascular graft, an occlusion device, a stent cover, or part of a prosthetic valve like a skirt or leaflet of a heart valve.

The invention also relates to a medical implant component comprising a piece of composite biotextile as described above, which textile has a cut edge that is coated (and/or impregnated) with polyurethane elastomer, i.e. the textile has a stable or stabilized cut edge which is not a (woven) selvage.

Other aspects include medical implants or medical devices, for example said orthopedic or cardiovascular devices, which devices comprise said medical implant component or said composite textile as described herein.

The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following exemplary embodiments and claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, and each separate value is incorporated into the specification as if it were individually recited herein. The use of any and all examples, or exemplary language (e.g., “such as” or “like”) provided herein, is intended merely to better illustrate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to practicing the invention.

Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. While certain optional features are described as embodiments of the invention, the description is meant to encompass and specifically disclose all combinations of these embodiments unless specifically indicated otherwise or physically impossible.

The various aspects and ways of performing aspects of the invention as described above, are now further summarized by a series of exemplary embodiments.

1) A method of making a composite biotextile suitable for use in or as a medical implant component, the method comprising steps of

-   -   Providing a textile comprising at least one strand having a         titer of 2-250 dtex and comprising fibers made from a         biocompatible and biostable synthetic polymer;     -   Determining locations on the textile where a cut is likely to be         made for an intended use of the textile;     -   Optionally pretreating the textile at least at the determined         locations on at least one side of the textile with a high-energy         source to activate the surface;     -   Solution coating the textile at least at the determined, and         optionally pretreated, locations on at least one side of the         textile with a coating composition comprising a biocompatible         and biostable polyurethane elastomer and a solvent for the         polyurethane;     -   Removing the solvent from the coated textile; and     -   Laser cutting the coated textile as obtained at least at a         coated location using an ultra-short pulsed laser;         to result in a composite biotextile wherein polyurethane is         present in an amount of 2.5-90 mass % based on composite         biotextile and polyurethane is at least present at a laser-cut         edge.         2) The method according to embodiment 1, wherein the textile is         a non-woven construct or a fabric, which fabric has been made         with a knitting, weaving or braiding technique.         3) The method according to any one of embodiments 1-2, wherein         the textile is a woven or knitted fabric, preferably a woven         fabric like a woven fabrics with a plain, twill, basket or leno         weave pattern.         4) The method according to any one of embodiments 1-3, wherein         the textile is a woven fabric containing different warp and weft         strands and has anisotropic properties.         5) The method according to any one of embodiments 1-4, wherein         the strands have a titer of at most 225, 200, 180, 160, 140,         120, 100, 80, 60 or 50 dtex, and of at least 4, 5, 6, 8, 10, 15,         or 20 dtex; for example a titer of 4-140, 6-100 or 8-60 dtex.         6) The method according to any one of embodiments 1-5, wherein         the textile comprises two or more strands, which have the same         or different linear density.         7) The method according to any one of embodiments 1-6, wherein         the textile contains at least 50 mass % of said at least one         strand and further contains other strands having different         characteristics, preferably the textile contains at least 60,         70, 80, 90, or 95 mass % of said at least one strand, or is made         from such at least one strand.         8) The method according to any one of embodiments 1-7, wherein         the textile has a thickness of at most 275, 250, 225, 200, 175,         150, 125, 100, 90, or 80 μm, and of at least 20, 25, 30, 35, 40         45, or 50 μm.         9) The method according to any one of embodiments 1-8, wherein         the at least one strand comprises at least one monofilament,         preferably with a titer of at least 2 and at most 50, 45, 40, 35         or 30 dtex.         10) The method according to any one of embodiments 1-8, wherein         the at least one strand consists of one or more multi-filament         yarns with a titer of at least 4, 5, 6, 8, 10, 15, or 20 dtex         and at most 250, 225, 200, 180, 160, 140, 120, 100, 80, 60 or 50         dtex, like a titer of 4-120, 5-80, or 6-60 dtex; and wherein         filaments of the yarn have a titer per filament of at least 0.2,         0.3 or 0.4 dtex and at most 5, 4, 3 or 2 dtex.         11) The method according to any one of embodiments 1-8, wherein         the textile is made from strands that comprise non-twisted         multi-filament yarn, like a UD textile construct wherein fibers         and filaments are preferably oriented in parallel.         12) The method according to any one of embodiments 1-11, wherein         the fibers are made from poly(meth)acrylates, polyolefins, vinyl         polymers, fluoropolymers, polyesters, polyamides, polysulfones,         polyacrylics, polyacetals, polyimides, polycarbonates, or         polyurethanes, including copolymers, compounds and blends         thereof.         13) The method according to any one of embodiments 1-12, wherein         the fibers are made from polyolefins like polyethylenes and         polypropylenes, preferably of high molar mass like ultra-high         molar mass polyethylene (UHMWPE); from polyketones; from         polyamides like aliphatic, semi-aromatic and aromatic         polyamides, like polyamide 6, polyamide 66 and their copolymers,         and poly(p-phenylene terephthalamide); or from polyesters like         aliphatic, semi-aromatic and aromatic polyesters, like         poly(l-lactic acid), polyethylene terephthalate (PET),         polytrimethylene terephthalate (PTT), polyethylene naphthalate         (PEN), polyethylene furanoate (PEF), and liquid crystalline         aromatic copolyesters.         14) The method according to any one of embodiments 1-13, wherein         the at least one strand has a tensile strength of at least 8         cN/dtex, and the polymer fibers preferably have a tensile         strength of at least 8, 9 or 10 cN/dtex.         15) The method according to any one of embodiments 1-14, wherein         the fibers have been made from one or more polyolefins selected         from homopolymers and copolymers containing one or more olefins         such as ethylene and propylene, and having a molar mass Mw of at         least 350 kDa.         16) The method according to any one of embodiments 1-15, wherein         the fibers have been made from a linear polyethylene such as a         high molecular weight polyethylene (HMWPE) or an ultra-high         molecular weight polyethylene (UHMWPE).         17) The method according to any one of embodiments 1-16, wherein         the fibers have been made from UHMWPE having an intrinsic         viscosity (IV) of 4-40 dL/g, preferably IV is at least 5, 6, 7         or 8 dL/g and at most 30, 25, 20, 18, 16 or 14 dL/g.         18) The method according to any one of embodiments 16-17,         wherein the UHMWPE is a linear or slightly branched polymer,         preferably a linear polyethylene having less than 1 side chain         per 100 carbon atoms; a side chain or branch containing at least         10 carbon atoms.         19) The method according to any one of embodiments 16-18,         wherein the UHMWPE is a single polymer grade, or a mixture of         polyethylene grades that differ in e.g. molar mass         (distribution), and/or type and amount of side chains or         comonomer(s).         20) The method according to any one of embodiments 16-19,         wherein the UHMWPE is a blend with up to 25 mass % of another         polyolefin.         21) The method according to any one of embodiments 16-20,         wherein the UHMWPE fibers have a tensile strength of at least         15, 20, 25, 28, 30 cN/dtex and typically of at most about 40, 37         or 35 cN/dtex; and a tensile modulus of 300-1500 cN/dtex.         22) The method according to any one of embodiments 1-21, wherein         the at least one strand comprises at least 80 or 90 mass % of         UHMWPE fibers with a tenacity of at least 15 cN/dtex, preferably         the strand substantially consists or consists of UHMWPE fibers.         23) The method according to any one of embodiments 15-22,         wherein the high molar mass polyolefin fibers, like UHMWPE         fibers, have been made by a so-called gel-spinning process.         24) The method according to any one of embodiments 1-23, wherein         the fibers contain at most 5, 4, 3, 2 or 1 mass % of additives.         25) The method according to any one of embodiments 1-24, wherein         the fibers contain at most 1000 ppm of a spin solvent,         preferably at most 500, 300, 200, 100 or 60 ppm.         26) The method according to any one of embodiments 1-25, wherein         the textile is a woven fabric with warp strands (substantially)         consisting of UHMWPE and weft strands (substantially) consisting         of another synthetic polymer, like a polyester such as PET;         alternatively weft strands consist of UHMWPE and warp strands of         another synthetic polymer, like PET.         27) The method according to any one of embodiments 1-26, wherein         the optional step of pretreating the textile at least at the         determined locations comprises a plasma or corona treatment, for         example a cold plasma treatment performed at atmospheric or         reduced pressure and at a temperature that does not negatively         affect the polyolefin fibrous construct.         28) The method according to embodiment 27, wherein the textile         has two opposite surfaces, and pretreating is done at least at         the determined locations on at least one side of the textile,         preferably on both sides at opposing and corresponding locations         of the textile.         29) The method according to any one of embodiments 27-28,         wherein pretreating is performed to activate substantially all         surface of the fibrous construct.         30) The method according to any one of embodiments 1-29, wherein         the coating composition comprises a polyurethane elastomer, a         solvent for the polyurethane, and optionally auxiliary         compounds; the polyurethane elastomer is a thermoplastic or a         thermoset polyurethane and soluble in a suitable solvent;         preferably the polyurethane elastomer is a thermoplastic         polyurethane (TPU).         31) The method according to any one of embodiments 1-30, wherein         the polyurethane elastomer comprises soft blocks derived from at         least one aliphatic polymer diol, chosen from the group         consisting of polyethers, polyesters, polyacrylates, polyolefins         and polysiloxanes,         32) The method according to any one of embodiments 1-31, wherein         the polyurethane elastomer comprises soft blocks derived from a         polysiloxane diol such as a poly(dimethyl siloxane) diol, an         aliphatic polyether like a poly(tetramethylene oxide) diol, an         aliphatic polyester, like an aliphatic polycarbonate such as a         poly(hexamethylene carbonate) diol or a poly(polytetrahydrofuran         carbonate) diol, or a combination thereof.         33) The method according to any one of embodiments 1-32, wherein         the polyurethane elastomer comprises soft blocks derived from a         polysiloxane diol and one or more of a polycarbonate diol and a         poly(tetramethylene oxide) diol.         34) The method according to any one of embodiments 1-33, wherein         the polyurethane elastomer comprises soft blocks having a molar         mass (Mn) of 200 to 100000 Da, preferably at least 400, 600, 800         or 1000 Da and at most 10000, 7500, 5000, 4000, 3000 or 2500 Da.         35) The method according to any one of embodiments 1-34, wherein         the polyurethane elastomer has a Shore hardness of at least 40,         50 or 60 ShA and at most 80, 70, or 60 ShD or at most 100, 90 or         85 ShA.         36) The method according to any one of embodiments 1-35, wherein         the polyurethane elastomer is linear and comprises a hydropobic         endgroup at least at one chain end, and preferably comprises an         average of two hydropobic endgroups.         37) The method according to any one of embodiments 1-36, wherein         the polyurethane elastomer has at least one hydrophobic endgroup         comprising a C₂-C₂₀ alkyl, a C₂-C₁₆ fluoroalkyl, a C₂-C₁₆         fluoroalkyl ether, a hydrophobic poly(alkylene oxide) or a         polysiloxane, like a poly(dimethyl siloxane), preferably the at         least one hydrophobic endgroup comprises a polysiloxane, like a         poly(dimethyl siloxane).         38) The method according to any one of embodiments 1-37, wherein         the hydrophobic endgroup is monomeric and has a molar mass of at         least 200, 300, or 500 Da and of at most 1,000 or 800 Da.         39) The method according to any one of embodiments 1-37, wherein         the hydrophobic endgroup is polymeric and has a molar mass of at         least 500, 1000, or 2000 Da and at most 10000, 8000, 6000 or         4000 Da.         40) The method according to any one of embodiments 1-39, wherein         the hydrophobic endgroup is present in an amount of at least         0.1, 0.2, 0.3, 0.4 or 0.5 mass %, and at most 3, 2 or 1 mass %,         based on the total mass of the polyurethane.         41) The method according to any one of embodiments 1-40, wherein         the polyurethane or TPU comprises one or more customary         additives selected from stabilizers, anti-oxidants, processing         aids, lubricants, surfactants, antistatic agents, colorants, and         fillers.         42) The method according to embodiment 41, wherein the amount of         additives is 0.01-5 or preferably 0.01-1 mass % based on the         amount of the polyurethane.         43) The method according to embodiment 41, wherein the         polyurethane or TPU is substantially free of additives.         44) The method according to any one of embodiments 1-43, wherein         the coating composition comprises polyurethane that is dried to         a level of less than 0.05 mass % of water before dissolving in         the solvent.         45) The method according to embodiment 30, wherein the coating         composition comprises a TPU that at a temperature above its         melting point shows a melt flow that is at least 10 times higher         than the melt flow of the synthetic polymer at said temperature;         for example at 210-240° C. the TPU has a melt flow index that is         at least 10, 20, 40, 60 or even 100 times the melt flow index of         the polymer.         46) The method according to any one of embodiments 1-45, wherein         the coating composition comprises a solvent that can dissolve         the polyurethane but not the polyolefin; preferably the solvent         is selected from tetrahydrofuran (THF), methyl-tetrahydrofuran         (m-THF), dimethylformamide (DMF), dimethylacetamide (DMAc),         dimethylsulfoxide (DMSO), dichloromethane, chloroform,         hexafluoro isopropanol, dioxane, dioxolane, mixtures thereof, or         mixtures thereof with other less good solvents.         47) The method according to any one of embodiments 1-46, wherein         the coating composition further contains one or more auxiliary         compounds, like an antibiotic agent, a pharmacological agent,         other biologics and small molecules to illicit a desired         biological response, or radiopacifying agents.         48) The method according to any one of embodiments 1-47, wherein         the coating composition has a Brookfield viscosity of at least         1, 5, 10, 25 or 50 mPa·s and at most 5000, 3000, 2000, 1000, or         500 mPa·s. about 1-5000 mPa·s.         49) The method according to any one of embodiments 1-48, wherein         solution coating is done by using a pipette or a syringe, by         dip-coating, by spray coating, by ink jet application, or by a         combination thereof.         50) The method according to any one of embodiments 1-49, wherein         solution coating is done in one step, or in multiple steps with         preferably a certain drying time between steps.         51) The method according to any one of embodiments 1-50, wherein         the coating composition is applied locally at selected locations         of the surface on one or both sides of the textile, or to all         surface area on one or both sides of the textile.         52) The method according to any one of embodiments 1-51, wherein         coating conditions and solution viscosity of the coating         composition are chosen such that a coating is formed either         predominantly on the surface of the textile, or also penetrates         between strands and fibers to partially or even fully cover the         fibers to result in a partially or fully impregnated textile.         53) The method according to any one of embodiments 1-52, wherein         the coating composition is applied to form one or more coating         stripes on the textile, preferably having a width of at least 1,         2 or 3 mm and at most 10, 8, 6, 5, or 4 mm.         54) The method according to any one of embodiments 1-53, wherein         removing the solvent is done by evaporation or washing,         preferably solvent is substantially removed at ambient         conditions or at a temperature at least 10° C. below the melting         temperatures of the polyurethane and the synthetic polymer.         55) The method according to any one of embodiments 1-54, wherein         removing the solvent results in a coated textile or composite         biotextile with a residual solvent content of less than 50 ppm.         56) The method according to any one of embodiments 1-55, wherein         laser settings are selected such that no excessive heating of         the coated textile occurs, to result in a composite biotextile         with at least one well-defined, regular and stabilized cut edge.         57) The method according to any one of embodiments 1-56, wherein         laser cutting is done with a pulsed laser, preferably with a         short pulse or ultra-short pulse laser, like a nano-, pico-, or         femtosecond pulsed laser.         58) The method according to any one of embodiments 1-57, wherein         laser cutting is done with a pulsed laser with an energy level         setting of 10-26 W, preferably 12-24, 14-22 or 16-20 W and a         cutting speed of 1-12 mm/s, preferably of 2-10 or 3-8 mm/s.         59) The method according to any one of embodiments 1-58, wherein         laser cutting at a coated location is done in multiple steps.         60) A composite biotextile for use in or as a medical implant         component as obtained by the method according to any one of         embodiments 1-59, having at least one cut edge where         polyurethane elastomer is present.         61) The composite biotextile according to embodiment 60, wherein         polyurethane is present in an amount of at least 5, 10, 15, 20         or 25 mass %, and of at most 80, 70, 60, 50, 40 or 30 mass %.         62) The composite biotextile according to any one of embodiments         60-61, wherein polyurethane is present in an amount of 0.2-10         mg/cm² based on composite textile, preferably in an amount of at         least 0.5, 1.0, 1.5, 2.0 or 2.5 mg/cm² and of at most 9, 8, 7,         6, or 5 mg/cm².         63) The composite biotextile according to any one of embodiments         60-62, having a thickness of 15-350 μm, preferably a thickness         of at least 20, 25, 30, 35, 40 45, or 50 μm and at most 325,         300, 275, 250, 225, 200, 175, 150, 125, 100, 90, or 80 μm.         64) The composite biotextile according to any one of embodiments         60-63, having a suture retention strength at the at least one         cut edge of at least 15 N, preferably of at least 20, 22 or 24 N         and at most about 50, 45 or 40 N.         65) A medical implant component comprising a composite         biotextile according to any one of embodiments 60-64, or as         obtained by the method according to any one of embodiments 1-59.         66) Use of the composite biotextile according to any one of         embodiments 60-64, or of the medical implant component according         to embodiment 65, in making a medical implant, preferably for         applications wherein the biotextile will be in contact with body         tissue or fluids, such as in orthopedic applications including         meshes for tissue reinforcement procedures or in cardiovascular         devices like a vascular graft, a stent cover, or a prosthetic         valve like a venous valve or heart valve.         67) A medical implant or medical device, for example for use in         orthopedic or cardiovascular applications, which implant or         device comprises the composite biotextile according to any one         of embodiments 60-64, or the medical implant component according         to embodiment 65.

The experiments and samples below further elucidate embodiments of the invention, but of course, should not be construed as in any way limiting the scope of the claims.

Examples and Comparative Experiments Materials

The polyolefin textile used as starting material in the experiments was a woven fabric with 2*2 twill weave pattern, of 45 mm flat width and thickness of about 70 μm, made from a medical grade, low-denier UHMWPE multi-filament yarn as warp and weft strands (Dyneema Purity® TG 10 dtex; available from DSM Biomedical BV, Sittard-Geleen NL).

As polyurethane elastomer following grades were used (available from DSM Biomedical BV, Sittard-Geleen NL):

-   -   CarboSil® TSPCU 20-80A; a thermoplastic silicone polycarbonate         polyurethane, having silicone endgroups, hardness 80 ShA, and         MFR 52 g/10 min (1.20 kg/224° C.);     -   Biospan® S SPU, a segmented polyether urethane comprising urea         groups and having silicone end groups, hardness about 74 ShA.

A medical grade microporous UHMWPE film (Dyneema Purity® membrane, available from DSM Biomedical BV, Sittard-Geleen NL) having thickness of about 15 μm and porosity of 83 vol % was used to laminate with woven fabric.

Methods Solution Viscosity

Solution viscosity at 25° C. is determined with a Brookfield DV-E viscometer with UL-adaptor and ULA-49EAY spindle, which is calibrated using silicone-based viscosity standards (Benelux Scientific).

Dip-Coating

Fabric samples of about 10-20 cm length are cut from the continuous woven UHMWPE fabric of about 45 mm width (described above); washed in heptane for 1 minute and dried at 40° C.; and then mounted length-wise at the short sides in a frame as sample holder.

Framed samples are pretreated by plasma activation during 60 s in a 15% oxygen atmosphere at 200 mTorr and 450 W.

Dip-coating is performed at ambient conditions by submersing a framed sample in a polymer solution and removing the samples with take-up speed of 0.1 m/sec; followed by drying at 40° C. for 20 minutes.

Fabric Thickness

Thickness of a fabric is measured using a Helios Preisser Electronic Outside Micrometer, with measuring range 0-25 mm (±0.001 mm).

Suture Retention Strength

Suture retention strength is measured on pieces of fabric of about 30*10 mm, through which a high-strength suture (FiberWire® 4.0) was inserted with a low-profile tapered needle in the center of the fabric and 2 mm from the edge of the short side. A Zwick Universal testing machine is used, equipped with a pneumatic Instron Grip (7 bar) and a Grip G13B, between which the looped suture and other end of the fabric are mounted with 50 mm grip-to-grip distance and preload of 0.05 N. The suture is then tensioned at test speed of 50 mm/min until failure of the sample. Suture retention strength is reported as the yield point of the measured pull out stress-strain curve (average+/−std; for 3 measurements), that is the force needed to pull the looped suture through the edge zone of the fabric.

Abrasion Resistance

Abrasion resistance of samples is tested using a Martindale 900 series Abrasion and Pilling Tester (James H Heal & Co. Ltd), applying ISO 12947-2 and ASTM D4966 as guidance. Half-moon shaped samples, matching the size of the circular sample holders of the tester were laser-cut from pieces of fabric, with the long edge in the warp direction. Samples are mounted in the specimen holders and rubbed with a forward- and backward translational movement or cycle (along the linear cut edge of a half-moon sample at 56 cycles/min) against a standard fabric (Abrasive cloth SM25, circular patch of 140 mm diameter) as abradant under 9 kPa loading weight. Samples (and micrographs thereof as taken with a Tagarno digital microscope at about 100* magnification) are visually inspected on wear, pilling, or other damage after 500, 1000, 2000, 3000, 4000, 8000, 10000 and 15000 cycles (for- and backward movements).

Hemocompatibility

Blood contact properties of samples are evaluated with the Chandler Blood Loop in vitro model. This closed system model has been reported in literature (DOI: doi: 10.1007/s10856-011-4335-2.) and is designed to investigate the effect of artificial surfaces to initiate the different and complex cascade of reactions intrinsic to human blood organ (e.g., coagulation, cell alteration, complement and inflammation). The model is in alignment with ISO 10993-4:2002. The Chandler Loop model provides material characteristics across a panel of hemocompatibility criteria, including thrombogenicity, coagulation, platelet number and activation, hemolysis, leukocyte activation, and complement activation. Whole blood from healthy donors is carefully drawn and minimally heparinized, and then gently circulated in rotating heparinized PVC tubing containing the test samples for 90 minutes in a thermostatic bath maintained at 37° C. Blood with no material contact is used as an internal model control; blood in contact with only the heparinized PVC tubing is used as a control. Blood is not pooled between donors but rather represents separate experiments, to be averaged at the end of the study. After 90 minutes incubation, test samples and circulating blood are collected and may be subjected to following analyses:

-   -   Thrombogenicity is analyzed by scanning electron microscopy on         the test sample surfaces. Fibrin, platelet, and leukocyte         adhesion to the surface is observed and compared between groups;     -   Coagulation is measured immunochemically (e.g., ELISA) targeting         coagulation factors XII, XI, and X—all of which modulate         prothrombin conversion and clotting. Thrombin-antithrombin-III         complex is also measured as a sensitive marker of coagulation         activation;     -   Platelet count is measured in the circulated blood using a cell         counter;     -   Quantifying a deficit in platelets in the circulating blood due         to exposure to material surfaces indicates perturbation of the         platelet behavior due to low hemocompatibility. Platelet         activation marker β-thromboglobulin is measured by ELISA;     -   Red and white blood cell count is measured using a cell counter         and is a general descriptor of hematologic effect;     -   Hemolysis is quantified by measuring free hemoglobin content in         the blood using a colorimetric biochemical assay;     -   Leukocyte activation is assayed by quantifying the enzymatic         marker PMN-Elastase; and/or     -   Complement activation is assayed by quantifying SC5b-9 marker of         complement complexation.

This panel of readouts typifies the blood contact properties of each material and an indication of the hemocompatibility of the composite materials can be made.

Sample Preparation and Suture Retention (Comparative Experiments 1-3 and Examples 4-6)

Suture retention strength of sample pieces of 100*30 mm that were laser cut from the non-modified UHMWPE fabric in both length (warp) and width (weft) directions were measured. Results summarized in Table 1 as comparative experiment 1 (CE1) relate to testing in weft direction; results obtained in warp direction were comparable.

The fabric pieces as cut with an ultra-short pulsed laser (USP laser; operated at 800 kHz, at 18 W, and cutting speed 5 mm/s) have straight and well-defined sharply cut edges. An example of such cut edge is shown in FIG. 1A, micrograph taken with a Tagarno digital microscope at about 150* magnification). An inserted suture, however, is rather easily pulled through the raveling fabric. Using higher energy upon laser cutting with a CO₂ laser operated in continuous mode at a low (10% of 100 W maximum power, cutting speed 35 mm/s; CM laser—low) and a higher setting (20% power, cutting speed 35 mm/s; CM laser—high) resulted in higher suture retention strength; but the cut edges of the fabric, however, are found to be unacceptably irregular with local thickening of partially molten and re-solidified fibers. The cut edges also feel rough to the fingers and stiffer than the fabric itself.

In comparative experiment 2 the UHMWPE fabric was heat-laminated at both sides by sandwiching between two sheets of microporous UHMWPE film (Dyneema Purity® membrane). The sandwich was placed between Teflon sheets in a hot platen press, heated for 10 min at 140° C. and 50 kN pressure, and cooled under pressure to room temperature in 15 minutes. Suture retention testing data for this CE2 fabric (see Table 1) indicates some strength increase when cut with ultra-short pulsed laser, and significantly improved strength for samples cut with higher energy CO₂ laser operated in continuous mode. Micrographs of the cut edges show irregular edges with lumps of molten and re-solidified material, increasing from pulsed to high intensity continuous mode laser cutting (see examples in FIG. 2). The thickness of the composite biotextile indicates that the materials were densified, and the modified fabric is markedly less flexible and pliable than the starting polyolefin fabric.

In experiment CE3 the UHMWPE fabric was treated with a CO₂ CM laser to weld the strands in the fabric together by partially melting, contacting and re-solidifying the surfaces. A piece of the fabric was laser treated to make fused zones, such that subsequently samples of desired size could be made using a USP laser; the samples having a fused edge zone of at least about 3 mm. Suture retention strength was found to be higher than for non-modified fabric, but not at the level found for CE2 samples (see Table 1).

In Example 4 the UHMWPE fabric was dip-coated in one step with a 10 mass % solution of a CarboSil® TSPCU 20-80A in THF (Lichrosolve); prepared by first drying the polyurethane pellets overnight at 70° C. and then stirring THF and pellets overnight at room temperature. This solution was found to have a Brookfield viscosity of about 180 mPa·s. Samples for suture retention testing were made with different (settings of) lasers as above; and results for testing in weft direction are in Table 1 (Ex4). This polyurethane-coated UHMWPE fabric shows markedly increased resistance to raveling when laser cut, seemingly independent of laser energy applied. The resulting edges, however, are dependent on the type of laser cutting: edges resulting from controlled energy cutting with a USP laser, at different settings, are well-defined and regular; whereas CM laser cutting produces irregular edges and stiffening. In FIG. 3 this is illustrated with some micrographs. FIG. 3A shows edges made with a USP laser applying 2 different energy levels, FIG. 3B is made of fabric edges resulting from cutting with a CM laser at low (left) and high settings (right). It will be clear that sample Ex4 produced via USP laser cutting is to be preferred for medical implant applications, for example because irregular edges may not only cause irritation after implantation but can also initiate further damage or failure of the composite biotextile upon extended use while being flexed etc.

These experiments thus demonstrate that a combination of providing a specific polyurethane coating to the fabric and cutting with a pulsed laser will enable making an improved composite biotextile that is suitable for use as an implant component that has proper suture retention strength.

In Experiments 5 and 6 the UHMWPE fabric was dip-coated with an 8 mass % solution of pre-dried Biospan® S SPU polyurethane in DMAc (Brookfield viscosity of about 220 mPa.$), by applying 1 layer (Ex5) and after intermediate drying a 2^(nd) layer of polyurethane (Ex6). Analogous to the observations for Ex4, USP laser cutting of coated fabric results in a composite fabric having stabilized and well-defined smooth edges, not showing the irregularities and thickening that occur upon laser cutting with a continuous mode laser.

TABLE 1 Suture retention strength Sample Suture retention strength (N) Amount of Cut with Cut with coating Thickness Cut with CM laser - CM laser - # Type of coating (mass %) (μm) USP laser low high CE1 None — 70 13.9 ± 3.0 43.5 ± 2.7 49.5 ± 5.1 CE2 Laminated with 2 — 81 22.9 ± 3.1 44.8 ± 4.9 39.0 ± 5.6 sheets of PE film CE3 None; Laser — 25.3 ± 0.8 nd nd welded Ex4 Carbosil, 1 coat 40.2 75 39.8 ± 3.1 40.1 ± 4.0 37.5 ± 5.6 Ex5 Biospan, 1 coat 43.3 73 24.0 ± 3.4 28.5 ± 8.3 33.3 ± 6.7 Ex6 Biospan, 2 coats 59.1 81 28.2 ± 5.9 34.8 ± 4.3 32.0 ± 6.4

Abrasion Resistance (CE7 and Ex8-10)

Abrasion resistance was determined as indicated above on samples as listed in Table 2, which samples correspond to those used in CE2 and Ex4-6 and were cut to size using the USP laser; resulting in straight and clean cut edges.

As summarized in Table 2, the unmodified woven sample CE7 showed already significant fraying and non-bound warp strands at the cut edge after 500 cycles, and broken filaments on the surface of the fabric. During further abrading cycles, damaging continued with loose filaments, increased fraying and unraveling, and ‘released’ warp yarns at the edge being broken and pull away. Three examples of micrographs of edges (at about 100* magnification) are shown in FIG. 5A. In contrast thereto, the coated fabrics showed markedly better resistance to fraying when submitted to the abrasion test. During testing of Example 8 (with Carbosil® coating) some broken filaments, indicating initial stage of fraying, were observed after 8000 cycles; but also after 15000 cycles only few damaged filaments at the edge were visible. Similarly, Examples 9 and 10, with 1 or 2 layers of Biospan® coating, showed only some broken filaments and hardly any fraying after 15000 cycles; see also Table 2 and FIGS. 5C-D.

TABLE 2 Abrasion testing Sample Amount of Abrasion resistance Type of coating (Observations after number of cycles) # coating (mass %) 1000 cycles 8000 cycles 15000 cycles CE7 none — Significant Severe fraying; Severe fraying; fraying; free damaged weft damaged weft warp strands and warp strands strands, broken filaments, outer warp strand gone Ex8 Carbosil 40.2 No visible Some damaged Very limited fraying change filaments Ex9 Biospan 1* 43.3 No visible Some damaged Very limited fraying change filaments Ex10 Biospan 2* 59.1 No visible Few damaged Very limited fraying change filaments

Hemocompatibility (CE11-12 and Ex13-15)

In these experiments, above-mentioned materials and a reference woven material, based on polyethylene terephthalate yarn (PET), were tested for their hemocompatibility in a Chandler Blood Loop in vitro model using human blood, as described above. The materials tested and a summary of results are provided in Table 3.

The commercially available PET woven (e.g. available as Dacron®, used as an aortic stent graft covering) was manually cut to sample size and used in CE11 as reference material. The non-coated UHMWPE fabric (same as above) was used in CE12. Examples 13-15 concern coated UHMWPE fabric, analogous to above Examples; test specimen of 5*80 mm were laser cut from larger pieces. All samples were sterilized twice with ethylene oxide prior to Chandler Loop testing. Blood circulating in heparinized PVC tubing and containing no test material served as an internal control for the model itself. All samples were individually tested in blood attained from five healthy human donors. Red and white blood cell counts, as well as levels of free plasma hemoglobin, hemoglobin, hematocrit, and SC5b-9 complement activation were found to be similar and stable within all materials. The results from each assay, wherein notable differences were observed between tested materials, are listed in Table 3; numbers given represent the mean value+/−the standard deviation (n=6).

Biologically relevant improvement in hemocompatibility between coated and non-coated UHMWPE was observed in thrombin-antithrombin complexes (TAT) concentration, demonstrating that both polyurethane coatings reduced the thrombogenicity, i.e blood coagulation activation, of the UHMWPE fabric according to this specific coagulation marker. All materials showed elevated TAT levels vs the control, but the uncoated and coated UHMWPE fabrics evoked 85-97% lower levels than the PET woven.

Other important differences were observed when comparing coated and uncoated UHMWPE versus PET. Specifically, platelet count was reduced for all samples, but was at significantly higher level for the (coated) UHMWPE materials than for PET woven. Levels of the platelet activation marker β-thromboglobulin (β-TG) were more than a factor 2 higher for PET than for uncoated and coated UHMWPE materials. The UHMWPE fabric twice coated with Biospan® polyurethane showed best performance in this assay. Finally, PMN-elastase, a pathologic indicator of granulocyte activation, was almost 2* higher for PET than for (uncoated and coated) UHMWPE fabrics.

TABLE 3 Hemocompatibility evaluation Results of in-vitro Chandler Loop model testing Platelet Sample TAT count β-TG PMN-elastase # Type of sample (μg/l) (10³/μl) (IU/ml) (ng/ml) Control PVC tube 93 ± 53 188 ± 24  906 ± 757 54 ± 35 CE11 PET woven; no 6374 ± 2759 103 ± 40 4192 ± 496 122 ± 40  coating CE12 UHMWPE woven; 1429 ± 857  165 ± 21 1881 ± 336 68 ± 14 no coating Ex13 UHMWPE woven; 318 ± 119 160 ± 27 1919 ± 996 69 ± 31 Carbosil coating (1 layer) Ex14 UHMWPE woven; 350 ± 229 170 ± 22 1922 ± 844 71 ± 36 Biospan coating (1 layer) Ex15 UHMWPE woven; 352 ± 188 172 ± 27 1459 ± 560 76 ± 26 Biospan coating (2 layers)

These in vitro hemocompatibility results demonstrate, the measured levels in several assays being comparable for (coated) UHMWPE fabric samples and the heparinized PVC tube containing no test material (internal control), that the present composite biotextiles show favorable hemocompatibility. The coated and uncoated UHMWPE fabrics even can be concluded to present superior hemocompatibility over the PET fabric that is frequently used in blood contact applications like stent-grafts. 

1. A method of making a composite biotextile for use in a medical implant comprising steps of: a. providing a textile comprising at least one strand having a titer of 2-250 dtex and comprising fibers made from a biocompatible and biostable synthetic polymer; b. determining a location on the textile where a cut is to be made based on an intended use of the textile; c. optionally pretreating the textile at least at the determined location on at least one side of the textile with a high-energy source to activate the surface; d. solution coating the textile at least at the determined, and optionally pretreated, location on at least one side of the textile with a coating composition comprising a biocompatible and biostable polyurethane elastomer and a solvent for the polyurethane; e. removing the solvent, thereby forming a coated textile; and f. laser cutting the coated textile at least at a coated location with an ultra-short pulse laser, thereby forming a composite biotextile.
 2. The method according to claim 1, wherein laser cutting is done with an energy level of 10-26 W and a cutting speed of 1-12 mm/s.
 3. The method according to claim 1, wherein the textile comprises a knitted, woven, or braided fabric.
 4. The method according to claim 1, wherein the at least one strand has a titer of 4-140 dtex.
 5. The method according to claim 1, wherein the textile contains at least 50 mass % of said at least one strand.
 6. The method according to claim 1, wherein the textile has a thickness of about 15-300 μm.
 7. The method according to claim 1, wherein the synthetic polymer is a polyethylene terephthalate (PET) or an ultra-high molecular weight polyethylene (UHMWPE).
 8. The method according to claim 7, wherein the strands comprise UHMWPE fibers having a tensile strength of 15-40 cN/dtex.
 9. The method according to claim 7, wherein the strands of the textile comprise at least 80 mass % of UHMWPE fibers.
 10. The method according to claim 1, wherein the polyurethane comprises at least one polymer chosen from the group consisting of polyethers, polyesters, polyacrylates, polyolefins and polysiloxanes.
 11. The method according to claim 1, wherein the polyurethane elastomer has a hardness from 40-100 ShA.
 12. The method according to claim 1, wherein the coating composition is applied on part of the surface area of both sides of the textile.
 13. A composite biotextile for use in a medical implant obtained by performing the method according to claim
 1. 14. A composite biotextile comprising: a textile containing at least one strand having titer of 2-250 dtex and comprising fibers made from UHMWPE; and a biocompatible and biostable polyurethane elastomer in an amount of 2.5-90 mass % based on composite biotextile, wherein the composite biotextile has at least one cut edge where polyurethane is present, and wherein the composite biotextile has a suture retention strength at said cut edge of at least 15 N, as measured with the method described in the experiments.
 15. A heart valve comprising the composite biotextile according to claim
 13. 16. The composite biotextile according to claim 13, wherein the polyurethane is present in an amount of 2.5-90 mass % based on total weight of the composite biotextile and polyurethane is present at least at a laser-cut edge.
 17. The method according to claim 1, wherein the textile is a woven fabric.
 18. The method according to claim 1, wherein the textile comprises one or more strands having a titer of 8-60 dtex.
 19. The method according to claim 1, wherein the polyurethane is a thermoplastic polyurethane comprising a polyether and a polysiloxane.
 20. The method according to claim 1, wherein the polyurethane is a thermoplastic polyurethane comprising a a polycarbonate and a polysiloxane. 